Structures Comprising Particles and Processes for Making Same

ABSTRACT

Structures, for example fibrous structures, such as absorbent material, for example absorbent core material including particles, for example super absorbent polymer particles (SAP particles), and processes for making same are provided.

FIELD OF THE INVENTION

The present invention relates to structures, for example fibrousstructures, such as absorbent material, for example absorbent corematerial comprising particles, and more particularly to fibrousstructures comprising particles, for example super absorbent polymerparticles (SAP particles), and processes for making same.

BACKGROUND OF THE INVENTION

For many hygienic applications, it is beneficial to integrate particles,such as SAP particles, of different size, shape, density, Stokes Number,and/or mass into a single structure, for example a fibrous structure,such as an absorbent material, for example an absorbent core material,to meet all desired performance requirements. These desired performancerequirements could include a combination of mechanical properties suchas softness and/or flexibility, and fluid handling properties forprotection against leaks and to keep skin dry when in contact with thestructure and/or products containing the structure.

In addition to the incorporation of particles into the structures,formulators have incorporated non-particle solid additives, such asfibers, for example pulp fibers.

Known non-limiting examples of solid additives (particles and/ornon-particles), for inclusion in the structure, for example fibrousstructure, such as absorbent core material, include fibers, such as: 1)pulp fibers for providing absorbency, flexibility and/or softness to thestructure, for example fibrous structure, such as an absorbent corematerial; 2) SAP particles to provide sufficient capacity for liquidretention (e.g. urine or menses) to the structure, for example fibrousstructure, such as an absorbent core material; 3) perfume particles toprovide scent generation; 4) odor controlling particles for controllingodors; 5) abrasive particles for providing abrasive properties to thestructure, for example fibrous structure, such as an absorbent corematerial; and 6) other inorganic and/or organic particles. However,known processes of integrating solid additives, such as fibers and/orparticles of different size, shape, and density and/or solid additives,such as fibers and/or particles that exhibit different Stokes Numbers,for example pulp fibers and SAP particles, into single structures, forexample fibrous structures, such as an absorbent core material, havebeen less than successful due to negatives associated with the resultingstructures. It is believed that the problems associated with using knownprocesses of integrating such solid additives into such structuresrelate, at least partially, to the use of a mixed solid additive stream,for example an air stream comprising mixed solid additives, for examplefibers, such as pulp fibers, and particles, such as SAP particles, inthe process for making the structure. Such a mixed solid additive streamcontaining a mixture of solid additives of different size, shape, and/ordensity and/or different Stokes Numbers results in differenttrajectories of the different solid additives based on their size,shape, density and/or Stokes Number and results in unacceptableformation of the structure, for example fibrous structure, such as anabsorbent core material because the fibrous structure may exhibit ahigher density, for example greater than 0.2 g/cm³ and/or the differentsolid additives may not be sufficiently integrated, distributed, and/orbe captured within the structure.

Prior Art FIG. 1A illustrates an example of a known process forintegrating solid additives; namely, particles and non-particle solidadditives, for example fibers, into a single structure, for example afibrous structure, such as an absorbent material, for example anabsorbent core material. As shown in Prior Art FIG. 1A, the process 10,oftentimes referred to as a coform process and/or a spinform process,comprises two meltblown polymer filament streams 12 each stream formedby extruding a molten thermoplastic material into converging highvelocity gas via knife edge dies 14 and a mixed solid additive stream 16comprising a mixture of fibers 18, for example pulp fibers, andparticles 20, for example SAP particles, that impinge the two meltblownfilament streams 12 where the two meltblown filament streams 12converge. The mixed solid additive stream 16 is injected into the twomeltblown filament streams 12 at an impingement zone 22 wherein the twomeltblown filament streams 12 converge. The fibers 18 and particles 20exhibit different size, shape, and/or density and different StokesNumbers. The two meltblown filament streams 12 each comprise a pluralityof meltblown filaments 24. The two meltblown filament streams 12 and themixed solid additive stream 16 are all open to ambient air and pressure.In other words, the streams 12 and 16 are not under a controlledenvironment and/or closed environment and/or enclosed in an enclosure,which can create negatives with the process, both formation of thestructure and hygiene of the process.

Due, at least in part, to the difference in the Stokes Numbers for thefibers 18, for example wood pulp fibers that exhibit a relatively lowStokes Number, and the particles 20, for example SAP particles thatexhibit relatively high Stokes Number, the air stream conveying anddelivering the mixed solid additive stream 16 to the impingement zone 22is unable to prevent at least a portion of the particles 20 from endingup on the top T and bottom B of the structure 26, for example fibrousstructure, such as absorbent material, as shown in Prior Art FIG. 1B.Since the particles 20 exhibit a higher, for example significantlyhigher, Stokes Number than the fibers 18, the particles 20 are prone torandom trajectories and thus is a non-controlled distribution of theparticles that result in the particles 20 being present at higherconcentrations near the upstream and downstream edges of the mixed solidadditive stream 16 unlike the fibers 18 which tend to be more uniformlydispersed or more concentrated in the inner portion of the mixed solidadditive stream 16. Having the particles 20, for example SAP particles,concentrated at the top T and bottom B of the structure 26 raises safetyand hygiene concerns due to the loose particles 20 readily becomingseparated from the structure 26 since they are not entrainedsufficiently within the plurality of inter-entangled filaments 24 of thestructure 26. Further, this known prior art process results instructures, for example fibrous structures, such as absorbent material,for example absorbent core material that exhibit a random arrangement ofthe particles within and/or on the resulting structure.

The problems described above with respect to the prior art process 10 asshown in Prior Art FIG. 1A and the resulting structure 26 as shown inPrior Art FIGS. 1B and 1C can be addressed by modifying the processconditions to ensure that a higher concentration of meltblown filaments24 are present at one or more of the top T and bottom B of the structure26 to sufficiently retain the particles 20 within the structure 26without negatively impacting the other desired properties of thestructure 26. However, these modifications fail to address thenon-controlled distribution of the particles 20 and the randomarrangement of the particles 20 in the composite fluid stream andultimately the resulting structure 26. Further, higher concentrations ofmeltblown filaments 24 in the top T and/or bottom B of the structure 26may lessen the integrity and/or mixing of the particles and filaments inthe overall the structure 26 by having lower concentrations of meltblownfilaments in other parts of the structure 26 and/or prevent fibers 18and/or particles 20 from becoming dislodged from the structure 26 duringmaterial handling of the structure 26, such as winding, slitting,unwinding, and converting into a finished absorbent material, such as afinished absorbent core material.

In addition, if the concentration (meaning amount and/or level, forexample mass per unit volume and/or % by weight) of meltblown filaments24 is too high on one or both sides (top T and/or bottom B), then themeltblown filaments 24 may create a fluid barrier at the structure'ssurface or surfaces. Such a fluid barrier will increase fluidacquisition times and/or reduce the performance, for example absorbencyperformance, of the structure 26 by inhibiting the structure's abilityto absorb fluids.

In light of the foregoing, the Prior Art FIG. 1A process 10 and itsresulting structure 26 as shown in Prior Art FIG. 1B exhibit negativesthat need to be solved.

Likewise, the process 10 as shown in Prior Art FIG. 2A also exhibitsnegatives that need to be solved. The process 10 as shown in Prior ArtFIG. 2A is another example of a known process for integrating solidadditives into a single structure, for example a fibrous structure, suchas an absorbent material, for example an absorbent core material. Unlikethe known process described above and in Prior Art FIG. 1A, the process10 shown in Prior Art FIG. 2A is performed under a controlledenvironment and/or closed environment and/or enclosed or substantiallyenclosed in an enclosure 28. As shown in Prior Art FIG. 2A, the process10, comprises a single meltblown polymer filament stream 12 formed byextruding a molten thermoplastic material via a filament source 30, inthis case a multi-row capillary die and at least one mixed solidadditive stream 16 comprising a mixture of fibers 18, for example pulpfibers, sourced from a fiber source (not shown) and particles 20, forexample SAP particles, sourced from a particle source (not shown). Theprocess 10 of Prior Art FIG. 2A may comprise one or more solid additivestreams 32, for example a fiber stream as shown in Prior Art FIG. 2Aand/or mixed solid additive streams 16, for example fibers 18 andparticles 20, that are added to the single meltblown polymer filamentstream 30 comprising a plurality of meltblown filaments 24. The fibers18 and particles 20 exhibit different size, shape, and/or density anddifferent Stokes Numbers. As a result, the fibers 18 and particles 20exhibit differences in their inertia also. Therefore, in order toachieve good mixing of the fibers 18 and particles 20, one would need arelatively straight path between the point of mixing and the collectiondevice. In the case of the process 10 of Prior Art FIG. 2A, the pathtraveled by the mixed solid additive stream 16 is not relativelystraight due to one or more bends in the path. Such bends result inseparation between with fibers 18 and the particles 20 due to differentStokes Numbers, which leads to poor mixing of the fibers 18 andparticles 20 within the mixed solid additive stream 16 and is considereda non-controlled distribution of the particles 20, which results in arandom arrangement of the particles within and/or on the resultingstructure 26.

In addition to the poor mixing of the fibers 18 and particles 20 by theprocess 10 of Prior Art FIG. 2A, the resulting structure 26 from theprocess 10 of Prior Art FIG. 2A as shown in Prior Art FIGS. 2B-2Dcontains substantially all of the particles 20 on one side, for examplethe top T side or portion of the resulting structure 26 as shown inPrior Art FIGS. 2B and 2C or the bottom B side or portion of theresulting structure 26 as shown in Prior Art FIG. 2D.

Even though individual SAP particles may follow slightly differenttrajectories depending on their respective individual sizes, shapes,densities, and Stokes Numbers, small and large SAP particles all stillseparate from the fibers during formation of the structure thusresulting in negatives in the structure.

In light of the foregoing, the Prior Art FIG. 2A process 10 and itsresulting structure 26 as shown in Prior Art FIG. 2B exhibit negativesthat need to be solved.

Commercially available SAP particles are typically manufactured in a waythat leads to a large distribution in particle size. Typical particlesizes are between 30 μm to 800 μm. Having both large and small particlesin the SAP particles can be advantageous. The benefits of smallerparticle is typically faster rate of absorption due to a highersurface-to-volume ratio. However, they tend to have a smaller capacity(liquid stored per gram of SAP material) and also have a tendency tocreate gel blocking. Gel blocking is detrimental to absorbent corematerial as it reduces the permeability and blocks passage ways forfluid to be spread within the absorbent structure to be blockedresulting in poor absorption and increased risk of fluid over flowing anarticle or wet sensation while wearing the product.

Conversely, the benefit of larger SAP particles is that they tend tohave a higher capacity per gram and so are more cost efficient to storea certain amount of liquid and they are also less likely to gel block.However, rate of absorption tends to be lower.

The difference in absorption performance between small and largeparticles has resulted in the SAP particle size distribution being a keyfactor for fluid handling performance of absorbent articles. (referencetypical optimization of fluid handling performance with g SAP per pad,and also z-direction gradient of concentration. Using only absolutelevels of SAP particles, and concentration in z-direction does not solvethe inherent trade-off between small and large particles)

To get the best performance out of a given particle size distribution,i.e. obtain the maximum absorption speed advantages and gram per gramcapacity while preventing gel blocking, it would be highly advantageousto separate the small particles (for speed of acquisition but prone togel blocking) from the large particles.

In particular it would be highly advantageous to enable a supply of SAPparticles with a wide size distribution, and then introduce them into afilament matrix such that the smaller particles preferentially locatetowards one side, for example the bottom, where gel blocking is less ofa concern, and preferentially locate larger particles towards theopposite side, for example the top, where permeability is important andsignificant presence of small SAP particles could be detrimental topermeability and performance. This is particularly true in productapplications where the fluid enters in several insults or over a longertime period where gel blocking of one insult can cause the next insultto not absorb well into the structure or in the case of a menstrualproduct if fluid is preferentially absorbed at the top, closer to thebody, leaving a wet wearing sensation. The effect of particle sizedistribution would be separate from the simple effects of controllingz-direction gradient of SAP concentration, i.e. structures that have amore uniform particle size distribution at any given plane in thez-direction of the substrate.

Fibrous structures comprising SAP particles are known in the art. Forexample, prior art coform processes utilizing converging air, knife-edgedie technology for making such fibrous structures are known in the art.However, the problem associated with such known fibrous structures andprior art processes is that the random distribution of the SAP particlesthroughout such known fibrous structures, especially in the z-direction,for example throughout the thickness of such known fibrous structures,is substantially uniform with respect to the SAP particle averageparticle size. In other words, large SAP particles and small SAPparticles are mixed and distributed randomly and substantially uniformlythroughout such known fibrous structures, especially in the z-direction,for example throughout the thickness of such known fibrous structures.Such a random and substantially uniform distribution throughout theknown fibrous structures results in negatives associated with theabsorbent performance of such known fibrous structures. In other words,the presence of smaller size SAP particles near one side of the fibrousstructure; namely, the side of the fibrous structure that is intended toreceive the initial insult of liquid, such as urine and/or menses whenthe fibrous structure is utilized as an absorbent core, results in thesmaller size SAP particles absorbing the liquid and creating gelblocking, which prevents at least a portion if not a substantial amountof the liquid from penetrating further into the thickness of the fibrousstructure for the absorbent core.

Formulators have attempted to correct these negatives associated withsuch known fibrous structures by starving the side of the known fibrousstructures of SAP particles such that there are less SAP particles(large and small particle size) near the side of the fibrous structurethat receives the initial insult and thus mitigates the gel blockingproblem. However, the SAP particles throughout the thickness of thefibrous structure continues to contain a random and substantiallyuniform mixture of large and small particle size SAP particles, there isno gradient of particle sizes of SAP particles within the thickness ofthe known fibrous structures, which still results in less than superiorabsorbent performance of the fibrous structures when utilized asabsorbent cores. A further problem with removal of SAP particlesentirely from the body facing side surface is the benefits in drynessthat SAP particles can deliver while wearing a product when used inmoderation close to the body to article interface.

Another problem seen in prior art processes as discussed above is theproblem with the integrating mixed solid additives, such as two or moredifferent (by size, shape, density, and/or Stokes Number) solidadditives, for example fibers, such as pulp fibers, and particles, suchas SAP particles, into a structure, such as a fibrous structure, forexample an absorbent material, such as an absorbent core material. Suchknown processes fail to effectively control the distribution of thesolid additives, for example high Stokes Number solid additives, inparticular the particles, within the resulting structure and/or fail toeffectively control the concentration of such solid additives throughoutthe resulting structure such that the particles are arranged in theresulting structure in a non-random arrangement.

Accordingly, there is a need for a process for integrating particles,such as SAP particles, into a structure, such as a fibrous structure,for example an absorbent material, such as an absorbent core material,that provides a controlled distribution of the particles resulting in astructure comprising a non-random arrangement of the particles withinthe structure and/or provides non-random arrangement of concentrationsof such particles throughout the resulting structure as well asresulting structures that overcome the negatives associated with knownfibrous structures comprising particles.

SUMMARY OF THE INVENTION

The present invention fulfills the needs described above by providing anovel process for integrating a plurality of particles into a pluralityof fibrous elements, for example filaments and/or fibers, for example astream of a plurality of filaments, such as a fluid stream comprising aplurality of fibrous elements, for example filaments, wherein a streamof a plurality of particles, for example a fluid stream comprising aplurality of particles, are mixed and/or added to the fluid streamcomprising the plurality of fibrous elements, for example filaments, bya controlled particle distribution process creating a non-randomarrangement of the plurality of particles in the resulting compositefluid stream comprising the plurality particles and the plurality offibrous elements, for example the plurality of filaments. Further, theresulting structure, for example a fibrous structure, such as anabsorbent material, for example an absorbent core material formed uponcollecting the composite fluid stream onto a collection device alsoexhibits a non-random arrangement of the plurality of the particles inthe resulting structure.

One solution to the problem identified above is a novel process forintroducing, such as mixing and/or adding, particles, for example afluid stream comprising a plurality of particles (a particle stream),into a fluid stream comprising a plurality of fibrous elements, forexample a plurality of filaments, (a fibrous element stream and/orfilament stream) in a controlled distribution, for example bycontrolling the angle and/or velocity at which the plurality ofparticles from the fluid stream comprising the plurality of particlesare introduced (mixed and/or added) into the filament stream such that acomposite fluid stream comprising a non-random arrangement of theparticles in the filament stream results. If the composite fluid streamis collected on a collection device, a resulting structure, for examplea fibrous structure, such as an absorbent material, for example anabsorbent core material comprising a non-random arrangement of theparticles in the structure is formed. In one example, the novel processmakes a fibrous structure comprising particles, such as SAP particles,that are present within the fibrous structure, especially thez-direction of the fibrous structure, in other words the thickness ofthe fibrous structure, such that a gradient, for example a continuousgradient of the particle sizes of the SAP particles is present within atleast a portion of the thickness of the fibrous structure. For example,the fibrous structure comprises SAP particles present within thethickness of the fibrous structure such that a higher concentration(meaning amount and/or level, for example mass per unit volume and/or %by weight) of larger size SAP particles relative to smaller size SAPparticles and/or less total smaller size SAP particles, are present nearthe side of the fibrous structure that will receive an initial insult ofliquid, for example urine and/or menses, when the fibrous structure isused as an absorbent core in an absorbent article. By having thisarrangement of sizes of SAP particles, gel blocking is mitigated and/orinhibited due to the relatively lesser amount and/or actual lesseramount of smaller size SAP particles present in that side of the fibrousstructure.

In one example of the present invention, a process for forming acomposite fluid stream, the process comprising the step of mixing, forexample commingling, such as coforming, a first fluid stream comprisinga plurality of fibrous elements, for example filaments and/or fibers,such as filaments, for example water-insoluble fibrous elements, such aswater-insoluble filaments, with a second fluid stream comprising aplurality of first particles, for example SAP particles, such that acomposite fluid stream (comprising the fibrous elements and firstparticles) exhibiting a non-random arrangement of the plurality of firstparticles in the composite fluid stream is formed, and optionally oralternatively such that a composite fluid stream (comprising the fibrouselements and first particles) exhibiting a non-random arrangement of theplurality of first particles in the composite fluid stream is formedsubstantially simultaneous with collecting the composite fluid stream ona collection device, and optionally, the step of collecting thecomposite fluid stream on a collection device, which may comprise anonwoven web material, such as a pre-existing nonwoven web material, forexample a top sheet, such as a secondary topsheet, such that a fibrousstructure exhibiting a non-random arrangement of the plurality of firstparticles in the fibrous structure is formed, is provided.

In another example of the present invention, a process for making afibrous structure, the process comprising the steps of:

a. providing a plurality of filaments;

b. providing a plurality of particles wherein the particles exhibit abroad range of particle size distribution, for example wherein theplurality of particles exhibit an average particle size distribution ofabout 300 μm and/or wherein the plurality of particles exhibit a rangeof particle sizes from about 45 μm to about 710 μm and/or greater than250 μm and/or greater than 400 μm and/or greater than 500 μm and/orgreater than 600 μm and/or greater than 700 μm (for example theplurality of particles may comprise particles having a particle size ofabout 700 μm and particles having a particle size of about 45 μm); and

c. commingling the plurality of filaments with the plurality ofparticles;

d. collecting the commingled plurality of filaments and plurality ofparticles on a collection device to form a fibrous structure, such thatthe plurality of particles are dispersed in the fibrous structure, in anon-random arrangement (for example based on the particle's size, shape,density, mass, Stokes Number), is provided.

In another example of the present invention, a structure, for example afibrous structure, that is made by the process of the present invention,is provided.

In another example of the present invention, a structure, for examplefibrous structure, comprising a plurality of fibrous elements, forexample filaments and/or fibers, such as filaments, and a plurality offirst particles, for example SAP particles, wherein the plurality offirst particles are arranged in the structure, for example fibrousstructure, in a non-random arrangement, is provided.

In another example of the present invention, a fibrous structurecomprising a plurality of filaments and a plurality of particles whereinthe plurality of particles are present in the fibrous structure in anon-random arrangement (for example based on the particles' size, shape,density, mass, Stokes Number), is provided.

In another example of the present invention, a process according to anyof the described processes of the present invention wherein thediameters, for example average diameters of the filaments as measuredaccording to the Average Diameter Test Method described herein vary inthe fibrous structure, for example vary by layers and/or by particletype inclusion and/or by beams laying down the filaments, with orwithout particles included.

In another example of the present invention, a process for making aparticle-containing fibrous structure, the process comprising the stepsof:

a. adding a plurality of first particles to a first stream of firstfilaments having a first average diameter to form a first compositestream;

b. collecting the first composite stream onto a collection device toform a first layer of the fibrous structure;

c. adding a plurality of second particles to a second stream of secondfilaments having a second average diameter different from the firstaverage diameter to form a second composite stream;

d. collecting the second composite stream directly onto the first layerof the fibrous structure to form a layered fibrous structure comprisingthe first layer and a second layer formed from the second compositestream, is provided.

In yet another example of the present invention, the fibrous structuresof the present invention exhibit a total fibrous structure (fibrouselements and particles) density of less than 0.2 g/cm³ and/or less than0.15 g/cm³ and/or less than 0.1 g/cm³.

Accordingly, the present invention provides a novel process for making acomposite fluid stream comprising fibrous elements, for examplefilaments, and particles, for example SAP particles, and a novelstructure, for example a fibrous structure, such as an absorbentmaterial, for example an absorbent core material, made from suchcomposite fluid stream and/or process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic representation of an example of a prior artprocess for combining particles and fibrous elements;

FIG. 1B is a schematic representation of an example of a prior artfibrous structure that can be produced by the prior art process of FIG.1A;

FIG. 1C is a schematic representation of another example of a prior artfibrous structure that can be produced by the prior art process of FIG.1A;

FIG. 2A is a schematic representation of an example of another prior artprocess for combining particles and fibrous elements;

FIG. 2B is a schematic representation of an example of a prior artfibrous structure that can be produced by the prior art process of FIG.2A;

FIG. 2C is a schematic representation of another example of a prior artfibrous structure that can be produced by the prior art process of FIG.2A;

FIG. 2D is a schematic representation of another example of a prior artfibrous structure that can be produced by the prior art process of FIG.2A;

FIG. 3A is a schematic representation of an example of a processaccording to the present invention;

FIG. 3B is a schematic representation of a distribution of particlesbased on particle size that can be produced by the process of FIG. 3A;

FIG. 3C is a schematic representation of an example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 3A;

FIG. 4A is a schematic representation of another example of a processaccording to the present invention;

FIG. 4B is a schematic representation of a distribution of particlesbased on particle size that can be produced by the process of FIG. 4A;

FIG. 4C is a schematic representation of an example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 4A;

FIG. 5A is a schematic representation of another example of a processaccording to the present invention;

FIG. 5B is a schematic representation of an example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 5A;

FIG. 5C is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 5A;

FIG. 5D is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 5A;

FIG. 6A is a schematic representation of another example of a processaccording to the present invention;

FIG. 6B is a schematic representation of an example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 6A;

FIG. 6C is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 6A;

FIG. 6D is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 6A;

FIG. 7A is a schematic representation of another example of a processaccording to the present invention;

FIG. 7B is a schematic representation of a distribution of particlesbased on particle size that can be produced by the process of FIG. 7A;

FIG. 7C is a schematic representation of an example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 7A;

FIG. 8A is a schematic representation of another example of a processaccording to the present invention;

FIG. 8B is a schematic representation of an example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 8A;

FIG. 8C is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 8A;

FIG. 8D is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 8A;

FIG. 8E is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 8A;

FIG. 8F is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 8A;

FIG. 8G is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 8A;

FIG. 8H is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 8A;

FIG. 8I is a schematic representation of another example of a fibrousstructure according to the present invention that can be produced by theprocess of FIG. 8A;

FIG. 9 is a schematic representation of an example of a processaccording to the present invention;

FIG. 10 is a schematic representation of an example of a processaccording to the present invention;

FIG. 11 is a schematic representation of an example of a processaccording to the present invention;

FIG. 12 is a particle size distribution profile of an example of aparticle according to the present invention;

FIG. 13 is a schematic representation of an example of a processaccording to the present invention for use with Process Examples 1-6;

FIG. 14A is a graph of the SAP particle size distribution profile (xaxis=Depth (mm) and y axis=Average Volume (mm³)) of the fibrousstructure made from Process Example 1a as measured according to the uCTTest Method described herein;

FIG. 14B is a graph of the SAP particle size distribution profile (xaxis=Depth (mm) and y axis=Sum Volume (mm³)) of the fibrous structuremade from Process Example 1a as measured according to the μCT TestMethod described herein;

FIG. 14C is a schematic representation of the fibrous structure madefrom Process Example 1a;

FIG. 15A is a graph of the SAP particle size distribution profile (xaxis=Depth (mm) and y axis=Sum Volume (mm³)) of the fibrous structuremade from Process Example 1b as measured according to the μCT TestMethod described herein;

FIG. 15B is a graph of the SAP particle size distribution profile (xaxis=Depth (mm) and y axis=Average Volume (mm³)) of the fibrousstructure made from Process Example 1b as measured according to the μCTTest Method described herein;

FIG. 16 is a magnified image of a portion of a ruler showing SAPparticles and pulp fibers;

FIG. 17A is an image showing a fibrous structure made according to thepresent invention on the left side, which shows larger SAP (AGM)particles closer to the top (less or no small SAP particles near top),which prevents less gel blocking, compared to a comparative fibrousstructure on the right side, which shows much more smaller SAP (AGM)particles closer to the top, which creates gel blocking during liquidabsorption from the top; and

FIG. 17B is an image showing a tape stripped portion from the top (T) ofthe fibrous structure on the left side in FIG. 17A (inventive fibrousstructure) and an image showing a tape stripped portion from the bottom(B) of the fibrous structure on the left side in FIG. 17A (inventivefibrous structure).

DETAILED DESCRIPTION OF THE INVENTION Definitions

“Non-random arrangement” as used herein with respect to 1) the presenceof particles in a composite fluid stream, for example the presence ofparticles in a composite fluid stream comprising a plurality of fibrouselements, for example filaments and/or fibers, such as filaments, and aplurality of the particles, means that a) the particles are present inthe composite fluid stream at different machine direction thicknesslocations in the composite fluid stream based on a particlecharacteristic selected from the group consisting of: size, shape, mass,density, Stokes Number, and mixtures thereof, for example size and/orStokes Number; and/or b) the particles are present in a machinedirection gradient in the composite fluid stream based on a particlecharacteristic selected from the group consisting of: size, shape, mass,density, Stokes Number, and mixtures thereof; and/or c) the particlesare present in the composite fluid stream at one or more localizedregions within the composition fluid stream's machine directionthickness (less than the composite fluid stream's entire orsubstantially entire machine direction thickness); and/or d) theparticles are present in the composite fluid stream at differentconcentrations (amount and/or level, for example % by weight, forexample based on composition of particle) in the composite fluidstream's machine direction thickness; and/or e) the particles arepresent in the composition fluid stream at one or more localized regionsof the composite fluid stream's cross machine direction dimension (lessthan the composite fluid stream's entire or substantially entire crossmachine direction dimension, for example the particles are present inone or more machine direction stripes); and/or 2) the presence ofparticles in a structure, for example a fibrous structure, such as anabsorbent material, for example an absorbent core material, comprising aplurality of fibrous elements, for example filaments and/or fibers, suchas filaments, and a plurality of the particles, means that a) theparticles are present in the fibrous structure at different z-directionthickness locations in the fibrous structure based on a particlecharacteristic selected from the group consisting of: size, shape, mass,density, Stokes Number, and mixtures thereof, for example size and/orStokes Number; and/or b) the particles are present in a z-directiongradient in the fibrous structure based on a particle characteristicselected from the group consisting of: size, shape, mass, density,Stokes Number, and mixtures thereof; and/or c) the particles are presentin the fibrous structure at one or more localized regions within thefibrous structure's z-direction thickness (less than the fibrousstructure's entire or substantially entire z-direction thickness);and/or d) the particles are present in the fibrous structure atdifferent concentrations (amount and/or level, for example % by weight,for example based on composition of particle) in the fibrous structure'sz-direction thickness; and/or e) the particles are present in thefibrous structure at one or more localized regions of the fibrousstructure's cross machine direction dimension (less than the fibrousstructure's entire or substantially entire cross machine directiondimension, for example the particles are present in one or more machinedirection stripes; and/or f) the particles are present in the structure,for example a fibrous structure, in i) a z-direction distribution suchthat the particles within the structure exhibit a z-direction gradientbased on the physical characteristics of the particles, such as size,shape, mass and/or Stokes Number; 2) a z-direction distribution and/orxy-direction distribution such that the particles within the structure,for example fibrous structure, are present within the structure, forexample fibrous structure, at different concentration levels, forexample in the z-direction and/or xy-direction; or 3) xy-directiondistribution such that the particles are present in discrete zoneswithin the structure, such zones may further exhibit z-directiondistribution of particles within a zone such that the particles exhibita z-direction gradient based on the physical characteristics of theparticles, such as size, shape, mass and/or Stokes Number and/or suchzones may further exhibit different concentration levels of particleswithin different zones.

“Fibrous structure” as used herein means a structure that comprises aplurality of filaments, for example a plurality of filaments and/or aplurality of fibers. In addition to the filaments, the fibrousstructures may comprise other materials such as particles, for exampleSAP particles, and/or pulp fibers. In one example, a fibrous structureaccording to the present invention means an orderly arrangement offilaments and particles within a structure in order to perform afunction, for example absorb liquids. In another example, a fibrousstructure according to the present invention is a nonwoven. In oneexample, the fibrous structures of the present invention may comprisecoform fibrous structures, meltblown fibrous structures, and spunbondfibrous structures so long as they contain particles. In one example,the fibrous structure is a non-hydroentangled fibrous structure. Inanother example, the fibrous structure is a non-carded fibrousstructure. In another example of the present invention, a fibrousstructure comprises a plurality of inter-entangled fibrous elements, forexample inter-entangled filaments, and particles dispersed between theinter-entangled filaments.

The fibrous structures of the present invention may be homogeneous,non-homogeneous, or layered. If layered, the fibrous structures maycomprise at least two and/or at least three and/or at least four and/orat least five layers.

The fibrous structures of the present invention may exhibit basisweights of from about 75 gsm to about 2000 gsm and/or from about 75 gsmto about 1500 gsm and/or from about 100 to about 1000 gsm. In oneexample, the fibrous elements, for example filaments, are present in thefibrous structures of the present invention at a basis weight of fromabout 20 gsm to about 1000 gsm and/or from about 40 gsm to about 800 gsmand/or from about 75 gsm to about 700 gsm and/or from about 100 gsm toabout 600 gsm. In one example, the particles, for example SAP particles,are present in the fibrous structures of the present invention at abasis weight of from about 10 gsm to about 1000 gsm and/or from about 20gsm to about 700 gsm and/or from about 40 gsm to about 600 gsm and/orfrom about 100 gsm to about 600 gsm and/or from about 150 gsm to about400 gsm.

“Multi-fibrous element fibrous structure” as used herein means a fibrousstructure that comprises filaments and fibers, for example a coformfibrous structure is a multi-fibrous element fibrous structure.

“Mono-fibrous element fibrous structure” as used herein means a fibrousstructure that comprises only fibers or filaments, for example ameltblown fibrous structure, such as a scrim, respectively, not amixture of fibers and filaments.

“Coform fibrous structure” as used herein means that the fibrousstructure comprises a mixture of filaments, such as filaments, forexample meltblown filaments, such as thermoplastic filaments, forexample polypropylene filaments, and SAP particles, and optionally pulpfibers, for example wood pulp fibers. The filaments, for examplefilaments and the SAP particles, and optionally the pulp fibers arecommingled together to form the coform fibrous structure. The coformfibrous structure may be associated with one or more meltblown fibrousstructures and/or spunbond fibrous structures, which form a scrim (orscrim layer that is deposited, for example spun directly onto a surfaceof a fibrous structure of the present invention that is beingconcurrently formed or that is already pre-formed and/or spun directlyonto a collection device prior to a fibrous structure of the presentinvention being formed (via spinning) directly on a surface of the scrimlayer (in one example the scrim may be present at a basis weight ofgreater than 0.5 gsm to about 5 gsm and/or from about 1 gsm to about 4gsm and/or from about 1 gsm to about 3 gsm and/or from about 1.5 gsm toabout 2.5 gsm), such as on one or more surfaces of the coform fibrousstructure.

The coform fibrous structure of the present invention may be made via asuitable coforming process.

“Filament” as used herein means an elongate particulate as describedabove that exhibits a length of greater than or equal to 5.08 cm (2 in.)and/or greater than or equal to 7.62 cm (3 in.) and/or greater than orequal to 10.16 cm (4 in.) and/or greater than or equal to 15.24 cm (6in.).

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers.Non-limiting examples of filaments include meltblown and/or spunbondfilaments. Non-limiting examples of polymers that can be spun intofilaments include natural polymers, such as starch, starch derivatives,cellulose, such as rayon and/or lyocell, and cellulose derivatives,hemicellulose, hemicellulose derivatives, and synthetic polymersincluding, but not limited to polyvinyl alcohol filaments and/orpolyvinyl alcohol derivative filaments, and thermoplastic polymerfilaments, such as polyesters, for example polyethylene terephthalate(PET), nylons, polyolefins such as polypropylene filaments, polyethylenefilaments, and polypropylene and polyethylene copolymer filaments, andbiodegradable or compostable thermoplastic fibers such as polylacticacid filaments, polyhydroxyalkanoate filaments, polyesteramidefilaments, and polycaprolactone filaments. The filaments may bemonocomponent or multicomponent, such as bicomponent filaments. In oneexample, the filaments are monocomponent filaments.

The filaments may be made via spinning, for example via meltblowingand/or spunbonding, from a polymer, for example a thermoplastic polymer,such as polyolefin, for example polypropylene and/or polyethylene,and/or polyester, for example polyethylene terephthalate (PET), andmixtures thereof. Filaments are typically considered continuous orsubstantially continuous in nature.

The filaments of the present invention may be spun from polymer meltcompositions via suitable spinning operations, such as meltblowingand/or spunbonding and/or they may be obtained from natural sources suchas vegetative sources, for example trees.

The filaments of the present invention may be monocomponent and/ormulticomponent. For example, the filaments may comprise bicomponentfibers and/or filaments. The bicomponent fibers and/or filaments may bein any form, such as side-by-side, core and sheath, islands-in-the-seaand the like.

“Meltblowing” is a process for producing filaments directly frompolymers or resins using high-velocity air or another appropriate forceto attenuate the filaments before collecting the filaments on acollection device, such as a belt, for example a patterned belt ormolding member. In a meltblowing process the attenuation force isapplied in the form of high speed air as the material (polymer) exits adie or spinnerette.

“Spunbonding” is a process for producing filaments directly frompolymers by allowing the polymer to exit a die or spinnerette and drop apredetermined distance under the forces of flow and gravity and thenapplying a force via high velocity air or another appropriate source todraw and/or attenuate the polymer into a filament.

“Fiber” as used herein means an elongate particulate as described abovethat exhibits a length of less than 5.08 cm (2 in.) and/or less than3.81 cm (1.5 in.) and/or less than 2.54 cm (1 in.). Pulp fibers, forexample wood pulp fibers typically exhibit a length of from about 0.7 mmto about 2.5 mm.

Fibers are typically considered discontinuous in nature. Non-limitingexamples of fibers include pulp fibers, such as wood pulp fibers, andsynthetic staple fibers such as polypropylene, polyethylene, polyester,copolymers thereof, rayon, lyocell, glass fibers and polyvinyl alcoholfibers.

Staple fibers may be produced by spinning a filament tow and thencutting the tow into segments of less than 5.08 cm (2 in.) thusproducing fibers; namely, staple fibers.

“Pulp fibers” as used herein means fibers that have been derived fromvegetative sources, such as plants and/or trees. In one example of thepresent invention, “pulp fiber” refers to papermaking fibers. In oneexample of the present invention, a fiber may be a naturally occurringfiber, which means it is obtained from a naturally occurring source,such as a vegetative source, for example a tree and/or plant, such astrichomes. Such fibers are typically used in papermaking and areoftentimes referred to as papermaking fibers. Papermaking fibers usefulin the present invention include cellulosic fibers commonly known aswood pulp fibers. Applicable wood pulps include chemical pulps, such asKraft, sulfite, and sulfate pulps, as well as mechanical pulpsincluding, for example, groundwood, thermomechanical pulp and chemicallymodified thermomechanical pulp. Chemical pulps, however, may bepreferred since they impart a superior tactile sense of softness tofibrous structures made therefrom. Pulps derived from both deciduoustrees (hereinafter, also referred to as “hardwood”) and coniferous trees(hereinafter, also referred to as “softwood”) may be utilized. Thehardwood and softwood fibers can be blended, or alternatively, can bedeposited in layers to provide a stratified web. Also applicable to thepresent invention are fibers derived from recycled paper, which maycontain any or all of the above categories of fibers as well as othernon-fibrous polymers such as fillers, softening agents, wet and drystrength agents, and adhesives used to facilitate the originalpapermaking.

In one example, the wood pulp fibers are selected from the groupconsisting of hardwood pulp fibers, softwood pulp fibers, and mixturesthereof. The hardwood pulp fibers may be selected from the groupconsisting of: tropical hardwood pulp fibers, northern hardwood pulpfibers, and mixtures thereof. The tropical hardwood pulp fibers may beselected from the group consisting of: eucalyptus fibers, acacia fibers,and mixtures thereof. The northern hardwood pulp fibers may be selectedfrom the group consisting of: cedar fibers, maple fibers, and mixturesthereof.

In addition to the various wood pulp fibers, other cellulosic fiberssuch as cotton fibers, cotton linters, rayon, lyocell, trichomes, seedhairs, rice straw, wheat straw, bamboo, and bagasse fibers can be usedin this invention. Other sources of cellulose in the form of fibers orcapable of being spun into fibers include grasses and grain sources.

“Trichome” or “trichome fiber” as used herein means an epidermalattachment of a varying shape, structure and/or function of a non-seedportion of a plant. In one example, a trichome is an outgrowth of theepidermis of a non-seed portion of a plant. The outgrowth may extendfrom an epidermal cell. In one embodiment, the outgrowth is a trichomefiber. The outgrowth may be a hairlike or bristlelike outgrowth from theepidermis of a plant.

Trichome fibers are different from seed hair fibers in that they are notattached to seed portions of a plant. For example, trichome fibers,unlike seed hair fibers, are not attached to a seed or a seed podepidermis. Cotton, kapok, milkweed, and coconut coir are non-limitingexamples of seed hair fibers.

Further, trichome fibers are different from non-wood bast and/or corefibers in that they are not attached to the bast, also known as phloem,or the core, also known as xylem portions of a non-wood dicotyledonousplant stem. Non-limiting examples of plants which have been used toyield non-wood bast fibers and/or non-wood core fibers include kenaf,jute, flax, ramie and hemp.

Further trichome fibers are different from monocotyledonous plantderived fibers such as those derived from cereal straws (wheat, rye,barley, oat, etc), stalks (corn, cotton, sorghum, Hesperaloe funifera,etc.), canes (bamboo, bagasse, etc.), grasses (esparto, lemon, sabai,switchgrass, etc), since such monocotyledonous plant derived fibers arenot attached to an epidermis of a plant.

Further, trichome fibers are different from leaf fibers in that they donot originate from within the leaf structure. Sisal and abaca aresometimes liberated as leaf fibers.

Finally, trichome fibers are different from wood pulp fibers since woodpulp fibers are not outgrowths from the epidermis of a plant; namely, atree. Wood pulp fibers rather originate from the secondary xylem portionof the tree stem.

“Particle” as used herein means a solid material, such as a powder,granule, agglomerate, encapsulate, microcapsule, and/or prill. The shapeof the particle can be in the form of spheres, rods, plates, tubes,squares, rectangles, discs, stars, or have regular or irregular randomforms such as a globular form. The particles of the present invention,at least those of at least 44 μm, can be measured by the Particle SizeDistribution Test Method described herein. For particles that are lessthan 44 μm, a different test method may be used, for example lightscattering, to determine the particle sizes less than 44 μm, for exampleperfume microcapsules that typically range from about 15 μm to about 44μm and/or about 25 μm in size.

As used herein, a particle is not a fiber as defined herein, however,particles may comprise recycled materials derived from fibers, forexample as a result of fibers being processed, for example recycled, bygrinding fibers into a finely-divided solid and re-incorporating saidfinely-divided solids into agglomerates, granules or other particleforms.

In one example, the particles of the present invention may compriserecycled material, compostable material, and/or biodegradable material.

The particles of the present invention may comprise SAP particles,perfume particles, odor controlling particles (such as zeolites,charcoal, activated charcoal, beta-cyclodextrin and mixtures thereof),abrasive particles (such as silica), and thickening, gelling particles,for example blood clotting material particles, such as chitosan,alginates, coagulants and other naturally occurring gelling and/orthickening particles. In one example, the particles comprise SAPparticles, especially when the structure, for example fibrous structureof the present invention will be utilized as an absorbent material, suchas an absorbent core material.

“SAP particles” as used herein is a material that absorbs liquids, forexample urine and/or menses, by transfer of the liquids across theperiphery of the material forming a gelatinous substance, which imbibesthe liquids and tightly holds the liquids. In one example, SAP particlesretain greater than 5 times their weight of deionized water whensubjected to centrifugal forces of less than or equal to 3000 G's for 10to 15 minutes. In comparison, typically capillary absorbents retainabout 1 times their weight under similar conditions. Non-limitingexamples of SAP particles include crosslinked polyacrylic acids and/orcrosslinked carboxymethyl cellulose.

SAP particle comprises a synthesized, cross-linked polymeric materialthat can absorb and retain, via hydrogen bonding and/or chemicalabsorption into its polymer chains (chemical storage) tens or evenhundreds of times its own weight in aqueous fluid. SAP particles are nowcommonly (although not exclusively) made from the polymerization ofacrylic acid blended with sodium hydroxide in the presence of aninitiator to form a poly-acrylic acid sodium salt (sometimes referred toas sodium polyacrylate). Other non-limiting examples of materials thatmay be used to make SAP particles include polyacrylamide copolymer,ethylene maleic anhydride copolymer, cross-linkedcarboxymethylcellulose, polyvinyl alcohol copolymers, cross-linkedpolyethylene oxide, and starch grafted copolymer of polyacrylonitrileand biological blood binding and/or blood clotting material particlesagents such as alginates. Current manufacturing sources of SAP particlessuitable for use in the processes and structures, for example absorbentmaterial, described herein include (but are not limited to) NipponShokubai (Osaka, Japan), BASF (Ludwigshafen (on the Rhine), Germany) andEvonik Industries (Essen, North Rhine-Westphalia, Germany).

In one example, the SAP particles comprise a highly crosslinked sodiumpolyacrylate that results in the SAP particles absorbing and retainingliquids, such as urine and/or menses, even under moderate pressure. SuchSAP particles are suitable for absorbent materials that can included indiapers, feminine care products, and/or adult incontinence products forexample.

In another example, the SAP particles comprise a lightly crosslinkedsodium polyacrylate that results in the SAP particles absorbing liquids,such as urine and/or menses, but release under moderate pressure. SuchSAP particles are suitable for absorbent materials that can be includedin floor cleaning pads, for example.

In one example, the SAP particles may comprise recycled material,compostable material, and/or biodegradable material.

In one example, the first particles, for example SAP particles maycomprise water-insoluble particles.

In one example, the first particles, for example SAP particles maycomprise water swellable particles.

Smaller SAP particles, for example SAP particles exhibiting an averageparticle size of less than 300 μm and/or less than 200 μm and/or lessthan 100 μm absorb liquids, for example urine and/or menses, faster thanlarger SAP particles, for example SAP particles exhibiting an averageparticle size of greater than 400 μm and/or greater than 500 μm and/orgreater than 600 μm.

“Stokes Number” or Stk is defined mathematically as

${Stk} = \frac{t_{p}}{t_{o}}$

“Particle Time Constant” or t_(p) is defined mathematically as

$t_{p} = \frac{\rho_{d}d_{d}^{2}}{18\mu_{g}}$

where □_(d) is the particle (“solid additive”) density, d_(d) is thegeometric mean of the major and minor particle axes, and □_(g) is theviscosity of the fluid carrying the particle, for example air.

“Fluid Time Constant” or t_(o) is defined mathematically as

$t_{o} = \frac{l_{o}}{v_{o}}$

where l_(o) is the length of interest in a region of analysis and v_(o)is the bulk velocity in the region of analysis

“Basis Weight” as used herein is the weight per unit area of a samplereported in lbs/3000 ft² or g/m² (gsm) and is measured according to theBasis Weight Test Method described herein.

“Machine Direction” or “MD” as used herein means the direction parallelto the flow of the fibrous structure through the fibrous structuremaking machine and/or sanitary tissue product manufacturing equipment.

“Cross Machine Direction” or “CD” as used herein means the directionparallel to the width of the fibrous structure making machine and/orsanitary tissue product manufacturing equipment and perpendicular to themachine direction.

“Different” as used herein with respect to particles, means two or moreparticles exhibit different properties for example different sizes,shapes, densities, masses, Stokes Numbers, and/or compositions.

“Ply” as used herein means an individual, integral fibrous structure.

“Plies” as used herein means two or more individual, integral fibrousstructures disposed in a substantially contiguous, face-to-facerelationship with one another, forming a multi-ply sanitary tissueproduct. It is also contemplated that an individual, integral fibrousstructure can effectively form a multi-ply sanitary tissue product, forexample, by being folded on itself.

“X” or “Y” or “xy”, and “Z” or “z” designate a conventional system ofCartesian coordinates, wherein mutually perpendicular coordinates “X”and “Y” define a reference X-Y (xy) plane, and “Z” defines an orthogonalto the X-Y plane. “Z-direction” designates any direction perpendicularto the X-Y plane. Analogously, the term “Z-dimension” means a dimension,distance, or parameter measured parallel to the Z-direction. When anelement, such as, for example, a molding member curves or otherwisedeplanes, the X-Y plane follows the configuration of the element.

“Non-elastic” as used herein means a material does not exhibit elasticproperties and/or elasticity and/or elastomeric.

“Particle size distribution span” as used herein means the(D90−D10)/D50×100%.

As used herein, the articles “a” and “an” when used herein, for example,“an anionic surfactant” or “a fiber” is understood to mean one or moreof the material that is claimed or described.

All percentages and ratios are calculated by weight unless otherwiseindicated. All percentages and ratios are calculated based on the totalcomposition unless otherwise indicated.

Unless otherwise noted, all component or composition levels are inreference to the active level of that component or composition, and areexclusive of impurities, for example, residual solvents or by-products,which may be present in commercially available sources.

Process for Making a Fibrous Structure

In one example as shown in FIG. 3A, an inventive process 50 of thepresent invention is a process for controlling the distribution ofparticles 20 within a structure 26, for example a fibrous structure,such as an absorbent material, for example an absorbent core material.In one example the fibrous structure made by the process of the presentinvention exhibits the properties and comprises the components suitablefor use in the process of the present invention. The process 50comprises the steps of commingling a particle stream 52 (a fluid streamcomprising a plurality of particles 20) (represented by an arrow)comprising a plurality of particles 20 with a filament stream 54 (afluid stream comprising a plurality of filaments 24) (represented by anarrow) comprising a plurality of filaments 24 to form a composite fluidstream 56 (composite stream 56) and collecting the composite stream 56on a collection device 25, for example a belt, such that a structure 26,for example a fibrous structure, such as an absorbent material, forexample an absorbent core material that exhibits a non-randomarrangement of the plurality of particles 20 in the structure is formed.

The plurality of particles 20 may be introduced into the process 50 by aparticle source 58, for example a hopper, by way of the particle stream52 originating from the particle source 58.

The plurality of filaments 24 may be introduced into the process 50 by afilament source 30, for example a die, such as a meltblow die and/orspunbond die, for example a knife edge die or a multi-row capillary die,examples of which are available from Biax-Fiberfilm Corporation ofGreenville, Wis., by way of the filament stream 54 originating from thefilament source 30.

The particle stream 52 may intersect the filament stream 54 at an angleα during the process 50. Angle α may range from about 5° to about 130°and/or from about 10° to about 110° and/or from about 20° to about 90°and/or from about 40° to about 90°.

In one example, the particle stream 52 and filament stream 54 intersectand commingle in a closed environment and/or substantially closedenvironment, for example an enclosure (housing) 60, such as a coformingbox, such that the filament source 30 and optionally the particle source58 are connected to and are in fluid communication with the enclosure 60as shown for example in FIG. 3A.

Further, as shown in FIG. 3A, the process 50 may be arranged as asingle-sided, single-injection of the plurality of particles 20, whichproduces a structure 26, for example a fibrous structure, such as anabsorbent material, for example an absorbent core material that exhibitsa non-random arrangement (a controlled distribution or designeddistribution) particle size distribution of particles 20 as shown inFIGS. 3B and 3C. The non-random arrangement particle size distributioncreates a structure, such as a fibrous structure, for example anabsorbent material, such as an absorbent core material that exhibits acontinuous gradient of relatively large particles, for examplerelatively higher Stokes Number particles on and/or near one side (thebottom B side) and relatively small particles, for example relativelylower Stokes Number particles on and/or near the opposite side (the topT side).

In another example as shown in FIG. 4A, an inventive process 50 of thepresent invention is a process for controlling the distribution ofparticles 20 within a structure 26, for example a fibrous structure,such as an absorbent material, for example an absorbent core material.The process 50 comprises the steps of commingling a particle stream 52(represented by an arrow) comprising a plurality of particles 20 with afilament stream 54 (represented by an arrow) comprising a plurality offilaments 24 to form a composite stream 56 and collecting the compositestream 56 on a collection device 25, for example a belt, such that astructure 26, for example a fibrous structure, such as an absorbentmaterial, for example an absorbent core material that exhibits anon-random arrangement of the plurality of particles 20 in the structureis formed.

The plurality of particles 20 may be introduced into the process 50 by aparticle source 58, for example a hopper, by way of the particle stream52 originating from the particle source 58.

The plurality of filaments 24 may be introduced into the process 50 by afilament source 30, for example a die, such as a meltblow die and/orspunbond die, for example a knife edge die or a multi-row capillary die,examples of which are available from Biax-Fiberfilm Corporation ofGreenville, Wis., by way of the filament stream 54 originating from thefilament source 30.

The particle stream 52 may intersect the filament stream 54 at an angleα during the process 50. Angle α may range from about 5° to about 130°and/or from about 10° to about 110° and/or from about 20° to about 90°and/or from about 40° to about 90°.

In one example, the particle stream 52 and filament stream 54 intersectand commingle in a closed environment, for example an enclosure(housing) 60, such as a coforming box, such that the filament source 30and optionally the particle source 58 are connected to and are in fluidcommunication with the enclosure 60 as shown for example in FIG. 4A.

Further, as shown in FIG. 4A, the process 50 may be arranged as asingle-sided, single-injection of the plurality of particles 20, whichproduces a structure, for example a fibrous structure, such as anabsorbent material, for example an absorbent core material that exhibitsa non-random arrangement (a controlled distribution or designeddistribution) particle size distribution as shown in FIGS. 4B and 4C.The non-random arrangement particle size distribution creates astructure, such as a fibrous structure, for example an absorbentmaterial, such as an absorbent core material that exhibits a continuousgradient of relatively large particles, for example relatively higherStokes Number particles on and/or near one side (the top T side) andrelatively small particles, for example relatively lower Stokes Numberparticles on and/or near the opposite side (the bottom B side).

In another example, the process 50 may be arranged as a single-sided,dual-injection (not shown) of the plurality of particles 20 such thattwo different particle streams 52 (a first particle stream and a secondparticle stream), which may comprise different particles 20 areintroduced into the filament stream 54. The intersection of thedifferent particle streams 52 with the filament stream 54 may occur atthe same spot or different spots along the filament stream 54. In stillanother example, the process 50 may be arranged as a single-sided,multi-injection of the plurality of particles 20 such that multiple(three or more) different particle streams 52, which may comprisedifferent particles are introduced into the filament stream 54. Theintersection of the different particle streams 52 with the filamentstream 54 may occur at the same spot and/or different spots along thefilament stream 54. The non-random arrangement (controlled distributionor designed distribution) particle size distributions for thesingle-sided, dual-injection and/or the single-sided, multi-injectionprocesses 50 would look similar to FIGS. 3B and 3C or 4B and 4C.

In even another example of the present invention, as shown in FIG. 5A,the process 50 comprises a first beam 62 comprising a filament source 30and a particle source 58 as described above with respect to FIG. 4A.Operation of the first beam 62 like the process described above withrespect to FIG. 4A results in a resulting structure 26 comprising anon-random arrangement of particles 20, for example a continuousgradient of particle sizes of the particles 20 within the resultingstructure 26. As shown in FIG. 5A, the resulting structure 26 comprisesa continuous gradient of particle sizes with larger size particles nearthe top T side and smaller size particles near the bottom B side. Afterforming the resulting structure 26, the top T side surface of theresulting structure 26 is then contacted with a second plurality offilaments 24 spun from a second filament source 30 from a second beam 64creating a layered structure 66, for example a fibrous structure, suchas an absorbent material, for example an absorbent core material, asshown in FIG. 5B. The second plurality of filaments 24 are spun directlyonto the top T side surface of the resulting structure 26 to form alayer of filaments 24, which may function as a scrim layer 68 to helpretain the particles 20 within the resulting structure 26. In the caseof FIG. 5B, the average fiber diameter of the filaments 24 in theresulting structure 26 and the filaments 24 in the scrim layer 68 arethe same or substantially the same.

The layered structures 66 shown in FIGS. 5C and 5D may also be formed bythe process 50 of FIG. 5A by producing different average fiber diameterfilaments 24 from at least two different beams. FIG. 5C shows an exampleof a layered structure 66 where the first beam 62 produces filaments 24exhibiting a smaller average fiber diameter than the filaments 24produced by the second beam 64, which creates the scrim layer 68. Theparticles 20 in the layered structure 66 of FIG. 5C are present in theresulting structure 26 in a non-random arrangement, for example acontinuous gradient of particle sizes. FIG. 5D shows another example ofa layered structure 66 where the first beam 62 produces filaments 24exhibiting a larger average fiber diameter than the filaments 24produced by the second beam 64, which creates the scrim layer 68. Theparticles 20 in the layered structure 66 of FIG. 5D are present in theresulting structure 26 in a non-random arrangement, for example acontinuous gradient of particle sizes.

In even yet another example of the present invention, as shown in FIG.6A, the process 50 comprises a first beam 62 comprising a filamentsource 30 and a particle source 58 as described above with respect toFIG. 3A. Operation of the first beam 62 like the process described abovewith respect to FIG. 3A results in a resulting structure 26 comprising anon-random arrangement of particles 20, for example a continuousgradient of particle sizes of the particles 20 within the resultingstructure 26. As shown in FIG. 6A, the resulting structure 26 comprisesa continuous gradient of particle sizes with larger size particles nearthe bottom B side and smaller size particles near the top T side. Afterforming the resulting structure 26, the top T side surface of theresulting structure 26 is then contacted with a second plurality offilaments 24 spun from a second filament source 30 from a second beam 64creating a layered structure 66, for example a fibrous structure, suchas an absorbent material, for example an absorbent core material, asshown in FIG. 6B. The second plurality of filaments 24 are spun directlyonto the top T side surface of the resulting structure 26 to form alayer of filaments 24, which may function as a scrim layer 68 to helpretain the particles 20 within the resulting structure 26. In the caseof FIG. 6B, the average fiber diameter of the filaments 24 in theresulting structure 26 and the filaments 24 in the scrim layer 68 arethe same or substantially the same.

The layered structures 66 shown in FIGS. 6C and 6D may also be formed bythe process 50 of FIG. 6A by producing different average fiber diameterfilaments 24 from at least two different beams. FIG. 6C shows an exampleof a layered structure 66 where the first beam 62 produces filaments 24exhibiting a smaller average fiber diameter than the filaments 24produced by the second beam 64, which creates the scrim layer 68. Theparticles 20 in the layered structure 66 of FIG. 6C are present in theresulting structure 26 in a non-random arrangement, for example acontinuous gradient of particle sizes. FIG. 6D shows another example ofa layered structure 66 where the first beam 62 produces filaments 24exhibiting a larger average fiber diameter than the filaments 24produced by the second beam 64, which creates the scrim layer 68. Theparticles 20 in the layered structure 66 of FIG. 6D are present in theresulting structure 26 in a non-random arrangement, for example acontinuous gradient of particle sizes.

In yet another example as shown in FIG. 7A, the process 50 may bearranged as a double-sided, dual-injection of the plurality of particles20 where a first particle stream 52 is introduced on one side of theenclosure 60, such as the upstream side of the enclosure 60 and/orprocess 50 and a second particle stream 52 is introduced on another sideof the enclosure 60, such as the downstream side of the enclosure 60and/or process 50. Such a process 50 as shown in FIG. 7A produces astructure, for example a fibrous structure, such as an absorbentmaterial, for example an absorbent core material that exhibits anon-random arrangement (a controlled distribution or designeddistribution) particle size distribution as shown in FIGS. 7B and 7C.The non-random arrangement particle size distribution creates astructure, such as a fibrous structure, for example an absorbentmaterial, such as an absorbent core material that exhibits a continuousgradient of relatively large particles, for example relatively higherStokes Number particles on and/or near one side (for example the top Tside) and relatively small particles to and through the center, forexample relatively lower Stokes Number particles, and then relativelylarge particles, for example relatively higher Stokes Number particles,which may be the same, similar, or different from the large particles onand/or near the top T side, on and/or near the opposite side (forexample the bottom B side). In another example, the process 50 may bearranged as a double-sided, dual-injection of the plurality of particles20 such that two different particle streams 52, which may comprisedifferent particles are introduced into the filament stream 54. Theintersection of the different particle streams 52 with the filamentstream 54 may occur at the same spot or different spots along thefilament stream 54. In still another example, the process 50 may bearranged as a double-sided, multi-injection of the plurality ofparticles 20 such that multiple (three or more) different particlestreams 52, which may comprise different particles are introduced intothe filament stream 54. The intersection of the different particlestreams 52 with the filament stream 54 may occur at the same spot and/ordifferent spots along the filament stream 54.

In addition to the controlled distribution of particles provided by theprocess of the present invention, the process 50 of the presentinvention as shown in FIG. 8A may optionally include, the addition of anon-particle solid additive stream 70 comprising a plurality ofnon-particle solid additives 72, for example fibers, such as pulpfibers, for example wood pulp fibers into the filament stream 54 and/orthe composite stream 56. In one example, the non-particle solidadditives 72, such as fibers, are kept separate from the particles 20prior to introduction into the enclosure 60 and/or prior to comminglingwith the filaments 24. Likewise, the particles 20 are kept separate fromthe non-solid additive particles 72, for example fibers, prior tointroduction into the enclosure 60 and/or prior to commingling with thefilaments 24.

As shown in FIG. 8A, an example of a process 50 of the present inventioncomprises the steps of: a) commingling a stream of filaments 54comprising a plurality of filaments 24 with a stream of non-particlesolid additives 70 comprising a plurality of non-particle solidadditives 72, for example fibers, such as pulp fibers, for example woodpulp fibers to form a mixed stream 74 comprising a plurality offilaments 24 and a plurality of non-particle solid additives 72; b)commingling a stream of particles 52 comprising a plurality of particles20 as described above with the mixed stream 74 to form a compositestream 56 and collecting the composite stream 56 on a collection device25, for example a belt, such that a structure 26, for example a fibrousstructure, such as an absorbent material, for example an absorbent corematerial that exhibits a non-random arrangement of the plurality ofparticles 20 in the structure is formed. Such a structure 26 comprises aplurality of filaments 24, a plurality of non-particle solid additives72, and a plurality of particles 20. The resulting structure 26comprising a non-random arrangement of particles 20 in the resultingstructure 26.

In the process 50 of the present invention as shown in FIG. 8A, theprocess 50 comprises the steps of commingling a non-particle solidadditive stream 70 (represented by an arrow) comprising a plurality ofnon-particle solid additives 72 with a filament stream 54 (representedby an arrow) comprising a plurality of filaments 24 to form a mixedstream 74; commingling a particle stream 52 (represented by an arrow)comprising a plurality of particles 20 with the mixed stream 74comprising a plurality of filaments 24 and a plurality of non-particlesolid additives 72 to form a composite stream 56 comprising theplurality of particles 20, the plurality of non-particle solid additives72, and the plurality of filaments 24; and collecting the compositestream 56 on a collection device 25, for example a belt, such that astructure 26, for example a fibrous structure, such as an absorbentmaterial, for example an absorbent core material that exhibits anon-random arrangement of the plurality of particles 20 in the structureis formed.

The plurality of particles 20 may be introduced into the process 50 by aparticle source 58, for example a hopper, by way of the particle stream52 originating from the particle source 58.

The plurality of filaments 24 may be introduced into the process 50 by afilament source 30, for example a die, such as a meltblow die and/orspunbond die, for example a knife edge die or a multi-row capillary die,examples of which are available from Biax-Fiberfilm Corporation ofGreenville, Wis., by way of the filament stream 54 originating from thefilament source 30.

The non-particle solid additives 72 may be introduced into the process50 from a non-particle solid additive source (not shown), for example ahopper and/or a disintegrator, and/or a pickering roll, and/or ahammermill if one or more of the latter three examples if thenon-particle solid additives 72 include fibers, such as pulp fibers, forexample wood pulp fibers.

The particle stream 52 may intersect the filament stream 54 at an angleα during the process 50. Angle α may range from about 5° to about 130°and/or from about 10° to about 110° and/or from about 20° to about 90°and/or from about 40° to about 90°.

The non-particle solid additive stream 70 may intersect the filamentstream 54 at an angle β during the process 50. Angle β may range fromabout 5° to about 130° and/or from about 10° to about 110° and/or fromabout 20° to about 90° and/or from about 40° to about 90°.

In one example, the non-particles solid additive stream 70, the filamentstream 54, particle stream 52 and filament stream 54 intersect andcommingle in a closed environment, for example an enclosure (housing)60, such as a coforming box, such that the filament source 30 andoptionally the particle source 58 are connected to and are in fluidcommunication with the enclosure 60 as shown for example in FIG. 3A.

Further, as shown in FIG. 8A, the process 50 may be arranged as asingle-sided, single-injection of the plurality of particles 20, whichproduces a structure 26, for example a fibrous structure, such as anabsorbent material, for example an absorbent core material that exhibitsa non-random arrangement (a controlled distribution or designeddistribution) particle size distribution of the particles 20 as shown inFIGS. 8B and 8C. The non-controlled distribution of the non-particlesolid additives 72, for example fibers, such as pulp fibers, for examplewood pulp fibers, results in a random and/or non-controlled arrangementof the non-particle solid additives 72 in the structure 26. Thenon-random arrangement particle size distribution creates a structure,such as a fibrous structure, for example an absorbent material, such asan absorbent core material that exhibits a continuous gradient ofrelatively large particles, for example relatively higher Stokes Numberparticles on and/or near one side (the bottom B side) and relativelysmall particles, for example relatively lower Stokes Number particles onand/or near the opposite side (the top T side) as shown in FIG. 8B,which would result from the set up shown in FIG. 8A if the MD directionwas opposite that shown or alternatively, if the particle stream 52 wasintroduced on the opposite side of the enclosure 60. The resultingstructure 26 as shown in FIG. 8C would result from the process 50 asshown in FIG. 8A where the structure 26, such as a fibrous structure,for example an absorbent material, such as an absorbent core materialexhibits a continuous gradient of relatively large particles, forexample relatively higher Stokes Number particles on and/or near oneside (the top T side) and relatively small particles, for examplerelatively lower Stokes Number particles on and/or near the oppositeside (the bottom B side) as shown in FIG. 8C.

The structure 26 shown in FIG. 8B may further include a scrim layer 68by modifying the process shown in FIG. 6A by replacing the first beam 62with the set up shown in FIG. 8A as modified to produce the structure 26shown in FIG. 8B. The resulting layered structure 66 is illustrated inFIG. 8D.

The layered structure 66 may further include filaments 24 in thestructure 26 layer and the scrim layer 68 that exhibit different averagefiber diameters as described above. For example, FIG. 8E shows filaments24 in the scrim layer 68 exhibiting a smaller average fiber diameterthan the filaments 24 in the structure 26 layer. Likewise, FIG. 8F showsfilaments 24 in the scrim layer 68 exhibiting a larger average fiberdiameter than the filaments 24 in the structure 26 layer.

The structure 26 shown in FIG. 8C may further include a scrim layer 68by modifying the process shown in FIG. 5A by replacing the first beam 62with the set up shown in FIG. 8A. The resulting layered structure 66 isillustrated in FIG. 8G.

The layered structure 66 may further include filaments 24 in thestructure 26 layer and the scrim layer 68 that exhibit different averagefiber diameters as described above. For example, FIG. 8H shows filaments24 in the scrim layer 68 exhibiting a smaller average fiber diameterthan the filaments 24 in the structure 26 layer. Likewise, FIG. 8I showsfilaments 24 in the scrim layer 68 exhibiting a larger average fiberdiameter than the filaments 24 in the structure 26 layer.

As discussed above, the average fiber diameters of filaments 24 producedfrom different filament sources 30, for example within the first beam 62and the second beam 64, can be achieved for example by utilizingdifferent velocities of attenuation air and/or different throughput ofthe polymer melt exiting the different filament sources 30.

Even though the processes 50 shown in FIGS. 5A and 6A only showexemplify two beams, the first beam 62 and the second beam 64, whichmakes a two layered structure 66, one or more additional beams, either abeam like the first beam 62 or a beam like the second beam 64 and/orboth, may be added to the processes 50. For example if the process 50comprises an additional beam like the second beam 64 that is positionedupstream (before) the first beam 62, then a first layer of a pluralityof filaments 24 are spun onto the collection device 25 creating a firstlayer, for example a first scrim layer. The composite stream 56 from thefirst beam 62 would then be spun directly onto the first scrim layer andthen a second scrim layer would be spun from the second beam 64 directlyonto the layer formed from the composite stream 56 of the first beam 62resulting in a three-layered structure with the structure 26 sandwichedbetween two scrim layers 68.

In one example, the angle α of intersection of the particle stream 52with the filament stream 54 and/or the mixed stream 74 (depending onwhich process 50 embodiment is being operated) and/or the velocity ofthe fluid, such as air, carrying the particles 20 in the particle stream52 can be varied and/or adjusted to control the distribution of theparticles 20 within the process 50 and ultimately in the resultingstructure 26, for example fibrous structure, such as an absorbentmaterial, for example an absorbent core material such that a non-randomarrangement of the plurality of particles 20 is created within thestructure.

One or more particle streams 52 may be introduced into the filamentstream 54 at any position within the enclosure 60 and/or process so longas the structure of the present invention is created. For example, oneparticle stream 52 may be introduced into the filament stream 54 at theupstream side of the enclosure 60 and/or process (for examplesubstantially parallel to the MD). Likewise, a particle stream 52 may beintroduced into the filament stream 54 at the downstream side of theenclosure 60 and/or process (for example substantially parallel to theMD).

In one example, the step of mixing the first fluid stream comprising aplurality of fibrous elements with the second fluid stream comprising aplurality of first particles occurs on the first fluid stream's upstreamside at two or more positions.

In another example, the step of mixing the first fluid stream comprisinga plurality of fibrous elements with the second fluid stream comprisinga plurality of first particles occurs on the first fluid stream'sdownstream side at two or more positions.

In one example, the process further comprises the step of mixing a thirdfluid stream comprising a plurality of fibers with the first fluidstream comprising a plurality of fibrous elements. In one example, thestep of mixing a third fluid stream comprising a plurality of fiberswith the first fluid stream comprising a plurality of fibrous elementscomprises commingling the plurality of fibers, for example pulp fibers,of the third fluid stream with the plurality of fibrous elements of thefirst fluid stream.

In one example, the process further comprises the step of mixing one ormore additional fluid streams comprising a plurality of additionalparticles different from the plurality of first particles. In oneexample the plurality of additional particles comprises a compositiondifferent from the first particles' composition. In one example, atleast one of the plurality of first particles exhibits a first StokesNumber that is different from at least one of the additional particles'Stokes Number.

In one example, the process further comprises the step of mixing afourth fluid stream comprising a plurality of second particles with atleast one of the first and second fluid streams. In one example, theplurality of second particles may be different from the plurality offirst particles. In one example, the plurality of second particles maybe the same as the plurality of first particles. In one example, thesecond and fourth fluid streams mix with the first fluid stream fromdifferent sides of the first fluid stream. In one example, the secondfluid stream mixes with the first fluid stream from the downstream sideof the first fluid stream and the fourth fluid stream mixes with thefirst fluid stream from the upstream side of the first fluid stream. Inone example, the second fluid stream mixes with the first fluid streamfrom the drive side of the first fluid stream and the fourth fluidstream mixes with the first fluid stream from the downstream side of thefirst fluid stream. In one example, the second fluid stream mixes withthe first fluid stream from the upstream side or the downstream side ofthe first fluid stream and the fourth fluid stream mixes with the firstfluid stream from the upstream side and the downstream side of the firstfluid stream.

In one example, the second and fourth fluid streams mix with the firstfluid stream from same side of the first fluid stream.

In another example, the process further comprises the step of collectingthe composite fluid stream on a collection device such that a fibrousstructure exhibiting a non-random arrangement of the plurality of firstparticles in the fibrous structure is formed. In one example, thenon-random arrangement of the plurality of first particles in thefibrous structure is based on a particle characteristic selected fromthe group consisting of: size, shape, mass, density, Stokes Number, andmixtures thereof. In one example, the particle characteristic is size,for example the non-random arrangement of the plurality of firstparticles in the fibrous structure comprises a first group of particlescomprising at least a majority of larger size particles present in afirst part of the fibrous structure's z-direction thickness and a secondgroup of particles comprising at least a majority of smaller sizeparticles present in a second part of the fibrous structure'sz-direction thickness different from the first part and/or the firstpart of the fibrous structure's z-direction thickness is more proximateto one side of the fibrous structure than the second part and/or thesecond part of the fibrous structure's z-direction thickness is moreproximate to one side of the fibrous structure than the first partand/or the first part of the fibrous structure's z-direction thicknessis proximate to one side of the fibrous structure and the second part ofthe fibrous structure's z-direction thickness is proximate to thefibrous structure's opposite side.

In one example, the plurality of first particles in the fibrousstructure is based on a particle characteristic Stokes Number, forexample, the non-random arrangement of the plurality of first particlesin the fibrous structure comprises a first group of particles comprisingat least a majority of larger Stokes Number particles present in a firstpart of the fibrous structure's z-direction thickness and a second groupof particles comprising at least a majority of smaller Stokes Numberparticles present in a second part of the fibrous structure'sz-direction thickness different from the first part, such as the firstpart of the fibrous structure's z-direction thickness is more proximateto one side of the fibrous structure than the second part and/or thesecond part of the fibrous structure's z-direction thickness is moreproximate to one side of the fibrous structure than the first partand/or the first part of the fibrous structure's z-direction thicknessis proximate to one side of the fibrous structure and the second part ofthe fibrous structure's z-direction thickness is proximate to thefibrous structure's opposite side.

In one example, the non-random arrangement of the plurality of firstparticles in the fibrous structure is such that the plurality of firstparticles are present in a z-direction gradient in the fibrous structurebased on a particle characteristic selected from the group consistingof: size, shape, mass, density, Stokes Number, and mixtures thereof, forexample, particle characteristic is size. In one example, thez-direction gradient is a continuous gradient, for example, thecontinuous gradient is present throughout the entire z-directionthickness of the fibrous structure. In one example, the z-directiongradient is present in less than the entire z-direction thickness of thefibrous structure. In one example, the particle characteristic of theplurality of first particles is Stokes Number, for example, thez-direction gradient is a continuous gradient, for example wherein thecontinuous gradient is present throughout the entire z-directionthickness of the fibrous structure. In one example, the z-directiongradient is present in less than the entire z-direction thickness of thefibrous structure.

In one example, the fibrous structure comprises a homogeneousz-direction concentration of the first particles.

In one example, the fibrous structure comprises a non-homogeneousz-direction concentration of the first particles.

In one example, the fibrous structure comprises two or more differentz-direction layers of concentration of the first particles.

In one example, the fibrous structure comprises two or more differentxy-plane regions of the first particles based on a particlecharacteristic selected from the group consisting of: size, shape, mass,density, Stokes Number, and mixtures thereof. In one example, the two ormore xy-plane regions of the first particles comprise two or morestripes of the first particles. In one example, at least one of the twoor more stripes of the first particles exhibits a z-direction gradientof the first particles within the at least one stripe of the firstparticles based on a particle characteristic selected from the groupconsisting of: size, shape, mass, density, Stokes Number, and mixturesthereof.

In one example, the fibrous structure comprises two or more differentxy-plane regions of the first particles based on different concentrationlevels of the first particles.

In one example, the fibrous structure comprises a first group of theplurality of first particles concentrated proximate a first third of thez-direction thickness of the fibrous structure and a second group of theplurality of first particles concentrated proximate the opposite thirdof the z-direction thickness of the fibrous structure, for example, thefirst group of the plurality of first particles exhibit a maximumparticle size that is at least two times the maximum particle size ofthe second group of the plurality of first particles, such as whereinthe first group of the plurality of first particles exhibit a maximumparticle size that is at least three times the maximum particle size ofthe second group of the plurality of first particles.

In one example, the process further comprises the step of depositing ascrim layer on at least one surface of the fibrous structure, forexample wherein the scrim layer comprises a plurality of scrimfilaments, for example water-insoluble filaments and/or thermoplasticfilaments, such as thermoplastic filaments comprising a polyolefin, forexample, a polyolefin selected from the group consisting of: propylene,ethylene, copolymers thereof, and mixtures thereof.

In one example, the process comprises two or more of the steps of mixinga first fluid stream comprising a plurality of fibrous elements and asecond fluid stream comprising a plurality of first particles.

In one example, the collection device of the process comprises anonwoven web material.

In one example, the plurality of first particles are present in thefibrous structure at a basis weight of from about 10 gsm to about 1000gsm.

In one example, the process for making a particle-containing fibrousstructure, the process comprising the steps of:

a. adding a plurality of first particles to a first stream of firstfilaments having a first average diameter to form a first compositestream;

b. collecting the first composite stream onto a collection device toform a first layer of the fibrous structure;

c. adding a plurality of second particles to a second stream of secondfilaments having a second average diameter different from the firstaverage diameter to form a second composite stream;

d. collecting the second composite stream directly onto the first layerof the fibrous structure to form a layered fibrous structure comprisingthe first layer and a second layer formed from the second compositestream.

In one example, the first average diameter is less than the secondaverage diameter, for example, wherein the first average diameter isless than 6 μm and/or from about 2 to about 5 μm.

In one example, the second average diameter is 6 μm or greater, forexample, wherein the second average diameter is from about 6 to about 10μm.

In one example, the first stream of first filaments further comprises aplurality of first fibers, for example pulp fibers, such as wood pulpfibers.

In one example, the plurality of first fibers is commingled with thefirst stream of first filaments, for example, wherein the commingling ofthe plurality of fibers with the stream of filaments occurscontemporaneously with the addition of the plurality of first particlesto the first stream of first filaments and/or wherein the commingling ofthe plurality of first fibers with the first stream of first filamentsoccurs prior to the addition of the plurality of first particles to thefirst stream of first filaments.

In one example, the step of adding a plurality of first particles to afirst stream of first filaments occurs within an enclosure.

In one example, the step of adding a plurality of first particles to afirst stream of first filaments occurs within a closed environment.

In one example, the step of adding a plurality of first particles to afirst stream of first filaments occurs at an addition angle of fromabout 30° to about 120°.

In one example, the plurality of first particles are homogeneouslydistributed in the layered fibrous structure in a non-random arrangementof the plurality of first particles in the layered fibrous structure,for example, wherein the non-random arrangement is a layereddistribution of the plurality of first particles in the fibrousstructure based upon one or more different particle characteristicswithin the plurality of particles.

The controlled distribution of particles of the present invention allowsparticles 20 to be placed within the resulting structure, for examplefibrous structure, such as an absorbent material, for example anabsorbent core material where desired in the x, y, and z directions, forexample in different regions and/or zones and/or stripes.

Further, the controlled distribution of particles of the presentinvention allows particles 20 to be placed within the resultingstructure, for example fibrous structure, such as an absorbent material,for example an absorbent core material where desired in the x, y, and zdirections, to create different regions and/or zones and/or stripesbased on concentration (meaning amount and/or level, for example massper unit volume and/or % by weight) of particles, types of particles,size of particles, densities of particles, mass of particles, StokesNumbers of particles, and/or shapes of particles.

FIG. 9 is a schematic representation of an example of a process 50 ofthe present invention. Related Table 1 below defines elements of FIG. 9.As shown in FIG. 9, the introduction of the particles (not shown) fromthe particle stream 52 from a particle source (not shown) via a nozzle75 and/or the filament stream 54 and/or the mixed stream 74 can beadjusted in a non-limiting manner such that the angle α may exhibit therange of angles described above.

TABLE 1 Code in FIG. 9 Definition Examples Region of The volumeenclosing the mixing of About 100 mm to 800 mm length × 100 mixingparticles and fibrous elements, for mm to 4000 mm depth × 100 mm to 1000example filaments and/or fibers, that mm height, for example about 200mm to create the composite fluid stream that about 600 mm and/or about300 mm to when collected on the collection device about 500 mm lengthand about 100 mm to forms the fibrous structure of the present about 500mm and/or about 200 mm to invention. about 400 mm depth and about 200 mmto about 800 mm and/or about 400 mm to about 600 mm height. CollectionThe collection device (collection belt) is Flat and horizontal, diagonalor vertical, device the device that collects the composite flat orcurved, in one example flat and (Collection fluid stream into a fibrousstructure and horizontal through laydown area belt) (25) provides areference point for all distances and angles. The collection device istypically in a horizontal position but could also be positionedvertically or at an angle vs ground level. The collection device willtypically have the shape of a single plane. However in case of anon-planar collection device, the angle of the collection device at thecenter of the laydown (line R) will serve as a reference point R R isthe hypothetical line that defines the Centered in region of mixing orshifted center of the laydown. It defines the towards 25 percentile ofupstream side of plane that separates the total mass of the region ofmixing, or 75 percentile of laydown into two equal parts, one sidedownstream of mixing, for example about upstream and one side downstreamof centered in region of mixing the line. R is perpendicular to thecollection belt Nozzles Device for injecting particles into the Openslot (uniform laydown) (75) mixing region. It typically has the shapePartially open slot (to create zones in MD of a nozzle, typically with awidth that containes high stokes particles) similar to, or slightly morenarrow, than Nozzle positioned in MD (injects in MD desired width of thelaydown of the direction), for example open slot position particles.Several nozzles can be used in MD (injects particles in MD direction)simultaneously to obtain the desired combination of distribution ofvarious particles embedded in the fibrous structure. The position of thenozzles can be changed both parallel to collection device as well asperpendicular to the collection device. Furthermore the angle of thenozzle, defined as a line between the tip of the nozzle and the pivotpoint of the nozzle, can be changed d1, d2 The minimum and maximumdistance d1 = about 5 mm to about 20 mm, for between the tip of thenozzle and the example 10 mm, d2 = about 500 mm to collection device(downstream side of about 2000 mm, for example 1000 mm the region ofmixing) (same as start of region of mixing in the above definition) e1,e2 The minimum and maximum distance e1 = about 5 mm to about 20 mm, forbetween the tip of the nozzle and the example about 10 mm, e2 = about100 mm collection device (upstream side of the to about 1000 mm, forexample about 300 region of mixing) mm (same as start of region ofmixing) Q1 Reference line perpendicular to the About 100 mm to about 500mm collection device that defines the pivot point of the of the nozzleon the downstream side of the mixing region Q2 Reference lineperpendicular to the collection device that defines the position of thetip of the nozzle on the downstream side of the mixing region d3Distance between Q2 and R. About 100 mm to 300 mm, for example about 200mm e3 Distance between S2 and R. About 100 mm to 300 mm, for exampleabout 200 mm Q2 Reference line perpendicular to the collection devicethat defines the pivot point for the nozzle A1, A2 The angle of a nozzleon downstream Between 5 and 130 degrees, for example side of the regionof mixing, defined as 20-90 degrees the angle between the line thatintersect the pivot point of the nozzle and the tip of the nozzle vs theQ1, with 0 degrees for a nozzle that would be pointing down towards thecollection device, and 45 degree pointing diagonally towards the mixingregion S1 Reference line perpendicular to the collection device thatdefines the pivot point of the of the nozzle on the downstream side ofthe mixing region S2 Reference line perpendicular to the collectiondevice that defines the position of the tip of the nozzle on thedownstream side of the mixing region B1, B2 The angle of a nozzle at theupstream Between 5 and 130 degrees, for example side of the region ofmixing, defined as 20-90 degrees the angle between the line thatintersect the pivot point of the nozzle and the tip of the nozzle vs theQ1, with 0 degrees for a nozzle that would be pointing down towards thecollection device, and 45 degree pointing diagonally towards the mixingregion

The integration of particles into a fibrous element stream, for examplea filament stream, to create a composite fluid stream comprising thefibrous elements, for example filaments, and the particles, andultimately create a fibrous structure upon collection of the compositefluid stream on a collection device, is not trivial, especially when theparticles are introduced through a separate fluid stream, for exampleair stream, comprising a plurality of the particles. Factors that mayinfluence this integration may include one or more of the following: 1)mass flow, velocity and angle of all other airflows, for example thefluid stream comprising the fibrous elements, because the fluid streamof the fibrous elements may require different properties and conditionsthan the fluid stream comprising the particles; 2) the Stokes Number ofthe particles, which involves physical properties such as particledensity, particle shape and particle size, will dictate the trajectoryof each particle depending on the angle and velocity of the particle asit enters the region of mixing; and 3) the desired distribution ofparticles in the x,y,z dimensions of the resulting fibrous structureboth in terms of particle intensity, for example concentration (such asmass ratio vs other materials at a given location) as well as particlesize (such as non-uniform particle size distribution)

Some of the complexity in achieving the desired particle distribution isillustrated in FIG. 10 where a combination of fluid streams, for exampleair streams, to deliver fibrous elements, for example filaments 24 froma filament source 30, such as a die, and a particle fluid stream 52(particle stream 52) comprising particles 20 is shown. The filamentstream at the point of particle integration (particle fluid stream 52mixing with the filaments 24) has a strong velocity profile, with thehighest velocity in the center of the region of mixing, and lower on theupstream and downstream side of the center. The actual trajectory ofeach particle 20 injected by the nozzle 75, is a function of its StokesNumber. Each particle's 20 angular acceleration (i.e. how sharply thetrajectory will bend towards the collection device) is then a functionof the local air velocity. This results in a complex path of travel forthe particles 20. In particular the larger Stokes Number particles 20may accelerate towards the collection device in the upstream half of themixing region. However if the velocity in the z-direction is higher thanthe surrounding air on the downstream side of the enclosure 60, it willdecelerate in the z-direction creating an inflection point. Furthermore,physical constraints such as the presence of sidewalls of the enclosure60 enclosing the region of mixing, may then result in larger particlesbouncing on the downstream sidewall of the enclosure 60, resulting inlarger particles being deposited further to the upstream side.

As shown in FIG. 11, the process of the present invention comprises thestep of mixing a first fluid stream comprising a plurality of fibrouselements, for example a filament stream 54 comprising a plurality offilaments 24 with a second fluid stream comprising a plurality of firstparticles 20, for example a particle stream 52 such that a compositestream 56 exhibiting a non-random arrangement of the plurality of firstparticles 20 in the composite fluid stream 56 is formed. As shown inFIG. 11, the step of mixing occurs within an enclosure 60. The mixingmay result the commingling of the filaments 24 and the particles 20, forexample the step of mixing may be a coforming process. The mixing of thefilament stream 54 with the particle stream 52 may occur at an angle αof from about 30° to about 120° and/or from about 45° to about 100°and/or from about 60° to about 90°. The particles 20 may exhibit a rangeof Stokes Numbers, for example a range of Stokes Numbers that exhibit atleast a 50 unit difference and/or at least a 100 unit difference and/orat least a 150 unit difference and/or at least a 200 unit differenceand/or at least a 250 unit difference. In one example, at least oneparticle 20 exhibits a size that is at least two times greater and/or atleast three times greater than the size of at least one other particle20. The introduction of the particle stream 52 may occur on the filamentstream's upstream side and/or downstream side.

As shown in FIG. 11, in one example of the present invention, the mixingof the particles 20 with the filaments 24 results in a non-randomarrangement of the particles 20 in the composite stream 56 based on aparticle characteristic selected from the group consisting of: size,shape, mass, density, Stokes Number, and mixtures thereof. In oneexample, the particle characteristic is size. In one example, thenon-random arrangement of the particles 20 in the composite stream 56comprises a first group 76 of particles 20 comprising at least amajority of larger size particles 20 present in a first part of thecomposite stream's 56 machine direction thickness and a second group 78of particles 20 comprising at least a majority of smaller size particlespresent in a second part of the composite stream's 56 machine directionthickness different from the first part. In one example, the first partof the composite stream's machine direction thickness is more proximateto the composite stream's 56 upstream side than the second part. Inanother example, the second part of the composite stream's 56 machinedirection thickness is more proximate to the composite stream's 56downstream side than the first part. In another example, the first partof the composite stream's 56 machine direction thickness is proximate tothe composite stream's 56 upstream side and the second part of thecomposite stream's 56 machine direction thickness is proximate to thecomposite stream's 56 downstream side.

As shown in FIG. 11, in one example of the present invention, the mixingof the particles 20 with the filaments 24 results in a non-randomarrangement of the particles 20 in the composite stream 56 based onStokes Numbers of the particles 20. In one example, the non-randomarrangement of the particles 20 in the composite stream 56 comprises afirst group 76 of particles 20 comprising at least a majority of largerStokes Number particles 20 present in a first part of the compositestream's 56 machine direction thickness and a second group 78 ofparticles 20 comprising at least a majority of smaller Stokes Numberparticles 20 present in a second part of the composite stream's 56machine direction thickness different from the first part. In oneexample, the first part of the composite stream's 56 machine directionthickness is more proximate to the composite stream's 56 upstream sidethan the second part. In another example, the second part of thecomposite stream's 56 machine direction thickness is more proximate tothe composite stream's 56 downstream side than the first part. Inanother example, the first part of the composite stream's 56 machinedirection thickness is proximate to the composite stream's 56 upstreamside and the second part of the composite stream's 56 machine directionthickness is proximate to the composite stream's 56 downstream side.

In another example, the non-random arrangement of the particles in thecomposite stream is such that the particles are present in a machinedirection gradient in the composite stream based on a particlecharacteristic selected from the group consisting of: size, shape, mass,density, Stokes Number, and mixtures thereof. In one example, theparticle characteristic is size. In another example the particlecharacteristic is Stokes Number. In one example, the machine directiongradient is a continuous gradient. In another example, the continuousgradient is present throughout the entire machine direction thickness ofthe composite stream. In another example, the machine direction gradientis present in less than the entire machine direction thickness of thecomposite stream.

a. Particles

The particle stream 52 may comprise less than 50% and/or less than 40%and/or less than 30% and/or less than 20% and/or less than 10% and/orless than 5% and/or less than 3% and/or 0% or about 0% by weight ofnon-particle solid additives, for example fibers, such as pulp fibers,for example wood pulp fibers.

The plurality of particles 20 of the particle stream 52 may exhibit aparticle size distribution span of greater than 10% and/or greater than15% and/or greater than 20% and/or greater than 25% and/or greater than30% and/or greater than 35% and/or greater than 40% and/or greater than45% and/or greater than 50%.

The plurality of particles 20 of the particle stream 52 may exhibit arange of Stokes Number, for example from about 50 to about 1000 and/orfrom about 80 to about 800 and/or from about 100 to about 600.

The plurality of particles 20 of the particle stream 52 may exhibit aStokes Number difference of less that 1000 and/or less than 800 and/orless than 600 and/or less than 500 and/or less than 400.

The plurality of particles 20 of the particle stream 52 may exhibit arange of average volumes of from about 0.0001 mm³ to about 0.001 mm³and/or from about 0.0002 mm³ to about 0.0009 mm³ and/or from about0.0003 mm³ to about 0.0009 mm³ and/or from about 0.0005 mm³ to about0.0008 mm³ and/or from about 0.0001 mm³ to about 0.0008 mm³ and/or fromabout 0.0001 mm³ to about 0.0006 mm³ as measured according to the μCTTest Method described herein.

The plurality of particles 20 of the particle stream 52 may exhibit anaverage volume difference of less than 0.001 mm³ and/or less than 0.0008mm³ and/or less than 0.0006 mm³ and/or less than 0.0005 mm³ and/or lessthan 0.0004 mm³ as measured according to the μCT Test Method described.

The plurality of particles 20 of the particle stream 52 may exhibit arange of densities of from about 0.1 g/cm³ to about 2.5 g/cm³ and/orfrom about 0.3 g/cm³ to about 2.0 g/cm³ and/or from about 0.5 g/cm³ toabout 2.0 g/cm³ and/or from about 0.7 g/cm³ to about 1.8 g/cm³ and/orfrom about 0.8 g/cm³ to about 1.8 g/cm³ and/or from about 1.0 g/cm³ toabout 1.5 g/cm³.

If the process comprises two or more particle streams 52 either in asingle beam and/or in multiple beams, the particles 20 within the two ormore particle streams 52 may be the same or different. In other gwords,the particles 20 within the two or more particle streams 52 may comprisedifferent compositions and/or exhibit different densities and/or exhibitdifferent particle characteristics, for example different particlecharacteristics selected from the group consisting of: size, shape,mass, density, Stokes Number, and mixtures thereof.

The plurality of particles 20 of the particle stream 52 may exhibitdifferent shapes, for example regular and/or irregular shapes. In oneexample, the plurality of particles 20 exhibit different irregularshapes.

The plurality of particles 20 of the particle stream 52 may be derivedfrom a particle material (not shown) that has been sieved, milled,and/or ground. FIG. 12 shows the Particle Size Distribution Profile ofan example of a plurality of particles that have been sieved and havebeen measured according to the Particle Size Distribution Test Methoddescribed herein. In addition to the Particle Size Distribution Profileof FIG. 12, which shows that the plurality of particles 20 exhibit a D50particle size of 300 μm, the plurality of particles 20 also exhibit theStokes Numbers and Mass % Particle Sizes set forth below in Table 2.

TABLE 2 Diameter mass % of Stokes (μm) particle size Number 710 0.1 548600 2.7 391 500 16.3 271 300 54.9 97 150 24.9 24 45 0.9 2

In addition, the particles of the present invention may further comprisetighter particle size distribution profiles such as are seen incolloidal SAP particles, which tend to be very spherical and exhibit aD50 of about 300 μm with a particle size range of from about 250 to 350μm. Examples of such colloidal SAP particles are commercially availablefrom Sumitomo.

The plurality of particles 20 of the particle stream 52 may comprisesuper absorbent polymer particles (SAP), perfume particles, abrasiveparticles, odor controlling particles, and mixtures thereof. In oneexample, the super absorbent polymer comprises carboxylic acid, forexample crosslinked carboxylic acid.

The plurality of particles 20 of the particle stream 52 may comprisegreater than 80% and/or greater than 90% and/or greater than 95% and/orabout 100% and/or 100% by weight of super absorbent polymer particles.

The super absorbent polymer particles may exhibit particle sizes over awide range. For reasons of industrial hygiene, average particle sizessmaller than about 30 microns are less desirable. Particles having asmallest dimension larger than about 2 mm may also cause a feeling ofgrittiness in the resulting structure, which is undesirable from aconsumer aesthetics standpoint. Furthermore, rate of fluid absorptioncan be affected by particle size. Larger particles have very muchreduced rates of absorption. In one example, super absorbent polymerparticles have a particle size of from about 30 microns to about 2 mmfor substantially all of the particles. “Particle Size” as used hereinmeans the weighted average of the smallest dimension of the individualparticles.

In one example, the plurality of particles exhibits a D50 particle sizeof from about 100 μm to about 5000 μm and/or from about 100 μm to about2000 μm and/or from about 250 μm to about 1200 μm and/or from about 250μm to about 850 μm as measured according to the Particle SizeDistribution Test Method.

In one example, the plurality of particles are present in the structureat a basis weight of from about 10 gsm to about 1000 gsm.

In one example, the plurality of particles comprises first particlescomprising a first composition and second particles comprising a secondcomposition different from the first composition.

In one example, the plurality of particles comprises first particlesexhibiting a first Stokes Number and second particles exhibiting asecond Stokes Number different from the first Stokes Number, for examplewherein the first Stokes Number is at least 20% and/or at least 30%different from the second Stokes Number.

b. Filaments

The filaments may comprise a polymer, for example a thermoplasticpolymer, such as a thermoplastic polymer is selected from the groupconsisting of: polyolefins, polyesters, polyesteramides,polycaprolactones, polyhydroxyalkanoates, polylactic acids, and mixturesthereof. In one example, the thermoplastic polymer is a polyolefin, suchas a polyolefin selected from the group consisting of: polypropylene,polypropylene copolymers, polyethylene, polyethylene copolymers, andmixtures thereof.

In one example, the thermoplastic polymer is a biodegradablethermoplastic polymer.

In one example, the thermoplastic polymer is a compostable thermoplasticpolymer.

Non-limiting examples of suitable polypropylenes for making thefilaments, for example filaments of the present invention arecommercially available from LyondellBasell and Exxon-Mobil.

Any hydrophobic or non-hydrophilic materials within the coform fibrousstructure, such as the thermoplastic filaments, for example thepolypropylene filaments, may be surface treated and/or melt treated witha hydrophilic modifier. Non-limiting examples of surface treatinghydrophilic modifiers include surfactants, such as Triton X-100.Non-limiting examples of melt treating hydrophilic modifiers that areadded to the polymer composition (polymer melt), such as thepolypropylene melt, prior to spinning filaments, include hydrophilicmodifying melt additives such as VW351 and/or S-1416 commerciallyavailable from Polyvel, Inc. and Irgasurf commercially available fromCiba. The hydrophilic modifier may be associated with the hydrophobic ornon-hydrophilic material at any suitable level known in the art. In oneexample, the hydrophilic modifier is associated with the polymercomposition, such as the hydrophobic and/or non-hydrophilic materialwithin the polymer composition at a level of greater than 0% to lessthan about 20% and/or greater than 0% to less than about 15% and/orgreater than 0.1% to less than about 10% and/or greater than 0.1% toless than about 5% and/or greater than 0.5% to less than about 3% by dryweight of the hydrophobic or non-hydrophilic material. In anotherexample, the hydrophilic modifier may be present in the filaments at alevel of from about 0.1% to about 10% and/or from about 0.5% to about 7%and/or from about 1% to about 5% by weight of the filaments.

c. Non-Particle Solid Additives

In one example, the non-particle solid additives of the presentinvention, for example fibers, such as pulp fibers, for example woodpulp fibers, may be selected from the group consisting of softwood kraftpulp fibers, hardwood pulp fibers, and mixtures thereof. Non-limitingexamples of hardwood pulp fibers include fibers derived from a fibersource selected from the group consisting of: Acacia, Eucalyptus, Maple,Oak, Aspen, Birch, Cottonwood, Alder, Ash, Cherry, Elm, Hickory, Poplar,Gum, Walnut, Locust, Sycamore, Beech, Catalpa, Sassafras, Gmelina,Albizia, Anthocephalus, and Magnolia. Non-limiting examples of softwoodpulp fibers include fibers derived from a fiber source selected from thegroup consisting of: Pine, Spruce, Fir, Tamarack, Hemlock, Cypress, andCedar. In one example, the hardwood pulp fibers comprise tropicalhardwood pulp fibers. Non-limiting examples of suitable tropicalhardwood pulp fibers include Eucalyptus pulp fibers, Acacia pulp fibers,and mixtures thereof.

In one example, the wood pulp fibers comprise softwood pulp fibersderived from the kraft process and originating from southern climates,such as Southern Softwood Kraft (SSK) pulp fibers. In another example,the wood pulp fibers comprise softwood pulp fibers derived from thekraft process and originating from northern climates, such as NorthernSoftwood Kraft (NSK) pulp fibers.

The wood pulp fibers, when present in the process and/or structure ofthe present invention may be present at a weight ratio of softwood pulpfibers to hardwood pulp fibers of from 100:0 and/or from 90:10 and/orfrom 86:14 and/or from 80:20 and/or from 75:25 and/or from 70:30 and/orfrom 60:40 and/or about 50:50 and/or to 0:100 and/or to 10:90 and/or to14:86 and/or to 20:80 and/or to 25:75 and/or to 30:70 and/or to 40:60.In one example, the weight ratio of softwood pulp fibers to hardwoodpulp fibers is from 86:14 to 70:30.

In one example, the non-particle solid additives of the presentinvention comprise one or more trichomes. Non-limiting examples ofsuitable sources for obtaining trichomes, especially trichome fibers,are plants in the Labiatae (Lamiaceae) family commonly referred to asthe mint family Examples of suitable species in the Labiatae familyinclude Stachys byzantina, also known as Stachys lanata commonlyreferred to as lamb's ear, woolly betony, or woundwort. The term Stachysbyzantina as used herein also includes cultivars Stachys byzantina‘Primrose Heron’, Stachys byzantina ‘Helene von Stein’ (sometimesreferred to as Stachys byzantina ‘Big Ears’), Stachys byzantina ‘CottonBoll’, Stachys byzantina ‘Variegated’ (sometimes referred to as Stachysbyzantina ‘Striped Phantom’), and Stachys byzantina ‘Silver Carpet’.

In another example, the non-particle solid additives of the presentinvention may comprise one or more super absorbent polymer fibers solong as the process and/or structure includes a plurality of particlesaccording to the present invention.

d. Forming the Structure

To ultimately form the structures 26 of the present invention, thecomposite stream 56 comprising a plurality of filaments 24 and aplurality of particles 20 and optionally a plurality of non-particlesolid additives 64 is collected on a collection device 25, for example athrough-air-drying fabric or other fabric or a patterned molding memberand/or a roller and/or a film and/or a pre-existing nonwoven webmaterial, for example a top sheet, such as a secondary topsheet, whichmay be carried upon an additional collection device, such as a fabric.This step of collecting the composite stream 56 on the collection device25 may comprise subjecting the resulting structure 26 while on thecollection device 25 to a consolidation step whereby the structure 26,while present on the collection device 25, is pressed between a nip, forexample a nip formed by a flat or even surface rubber roll and a flat oreven surface or patterned, heated (with oil) or unheated metal roll.

The collection step onto the collection device may be vacuum assisted bya vacuum box under the collection device 25.

In one example, the filament source 30 of the process 50 may be meltblowdie, for example a multi-row capillary die, a knife-edge die, andcombinations thereof. In one example, the meltblown die is a multi-rowcapillary die. In one example, the multi-row capillary die comprises aplurality of filament-forming holes which is positioned coaxially withina fluid-releasing hole that provides attenuation air to the polymerexiting the filament-forming holes. The fluid-releasing hole may beconcentrically or substantially concentrically positioned around thefilament-forming hole. In one example, the fluid, for exampleattenuation air, exits one of more, for example each fluid-releasinghole parallel or substantially parallel to the filament exiting the oneor more filament-forming holes.

In one example of the process 50 of the present invention, the processcomprises the steps of:

a. providing a plurality of filaments;

b. providing a plurality of particles and optionally non-particle solidadditives, wherein at least a portion of the plurality of solidadditives comprises a plurality of particles, wherein the particlesexhibit a broad range of particle size distribution; and

c. commingling the plurality of filaments with the plurality of solidadditives;

d. collecting the commingled plurality of filaments and plurality ofsolid additives on a collection device to form a structure such that theplurality of particles are non-uniformly dispersed in the fibrousstructure based upon their particle size.

In one example, the process comprises the steps of: a) providing astream of filaments comprising a plurality of filaments, a stream ofparticles comprising a plurality of particles, for example a pluralityof SAP particle, and optionally a stream of non-particle solid additivesall streams being separate from one another and/or neat streams (forexample less than 10% and/or less than 5% and/or less than 3% and/orabout 0% and/or 0% by weight of material different from their respectivematerials); b) commingling the plurality of particles with the pluralityof filaments; c) optionally commingling the plurality of non-particlesolid additives with the plurality of filaments; d) collecting thefilaments, particles, and optionally non-particle solid additives on acollection device to form a structure, such as a fibrous structure, forexample an absorbent material, such as an absorbent core material.

In one example, the particles and non-particle solid additives, such asfibers, for example wood pulp fibers, may be introduced into thefilament stream as a solid additive (particle and non-particle) stream.In such a case, the amount by weight of the non-particle solid additivesmay be relatively low compared to the amount by weight of the particlesas described above. Further, the plurality of particles may exhibit atleast one Stokes Number and the plurality of pulp fibers may exhibit atleast one Stokes Number different from the at least one Stokes Number ofthe plurality of particles. In one example, at least one Stokes Numberof the plurality of particles is at least 20% and/or at least 30%different from the at least one Stokes Number of the plurality ofnon-particle solid additives.

As described above, the step of commingling in the process may occurwithin an enclosure (housing), for example a forming box, such as acoforming box.

In one example, the step of commingling the plurality of filaments withthe plurality of particles comprises introducing the plurality ofparticles into a stream of the plurality of filaments at an angle offrom about 10° to about 170° and/or from about 20° to about 150° and/orfrom about 30° to about 130° and/or from about 30° to about 120° and/orfrom about 45° to about 100° and/or from about 60° to about 90° relativeto the stream of the plurality of filaments.

In one example, the plurality of particles are non-uniformly distributedwithin the fibrous structure such that particles concentrated near oneside of the fibrous structure exhibit a particle size that is at leasttwo times the particle size of the particles concentrated near theopposite side of the fibrous structure. The plurality of particles maybe non-uniformly distributed within the fibrous structure such thatparticles concentrated near one side of the fibrous structure exhibit aparticle size that is at least three times the particle size of theparticles concentrated near the opposite side of the fibrous structure.

In one example, the plurality of particles are non-uniformly distributedwithin the fibrous structure such that particles concentrated near afirst third of the caliper of the fibrous structure exhibit a particlesize that is at least two times the particle size of the particlesconcentrated near the opposite third of the caliper of the fibrousstructure. The plurality of particles may be non-uniformly distributedwithin the fibrous structure such that particles concentrated near afirst third of the caliper of the fibrous structure exhibit a particlesize that is at least three times the particle size of the particlesconcentrated near the opposite third of the caliper of the fibrousstructure.

Non-Limiting Process Examples for Making Structures of the PresentInvention

The following non-limiting examples, Process Examples 1-6, are madeutilizing an example of a process 50 according to the present inventionas shown in FIG. 13. FIG. 13 comprises multiple beams A-E, for exampleparticle mixing beams A-C and scrim beams D-E.

A given process may utilize one or more particle mixing beams A-C.Further, a given process may additionally use one or more scrim beamsD-E. The various Process Examples 1-6 utilize different materials,different conditions, and/or different number of beams and/orconfigurations.

As shown in FIG. 13, the Process Examples 1-6 may utilize a single beam,two beams, three beams, and/or more, for example the beams may comprisesimply a die to spin filaments onto the collection device and/or onto asurface of the particle-containing structure formed on the collectiondevice or both, thus creating a scrim layer from the beam, which isreferred to as a scrim beam.

For a multi-beam system, the following is defined: A series of beams,(beam A, beam B, beam C, etc.) with each beam letter defined by in whichorder it deposits material onto a collection device 25 (beam A lays downon naked collection belt or scrim layer riding on the collection belt oreven on a pre-existing nonwoven web material riding on the collectionbelt, beam B lays down on material (for example fibrous structure)already deposited by beam A, beam C lays down material onto materialalready deposited by beam A and beam B.

Each beam integrates at least one or more different material classes,

Discrete short fibers=72 (e.g. semi-treated or fully treated pulp, EUCfibers, CS10 fibers, and mixtures thereof)

Continuous filaments=24 (e.g. meltblown fibers, such as PP, PE, otherpoly-olefins, PLA, PHA, block co-polymers, such as Vistamaxx)

Particles=20 (such as SAP, perfume microcapsules, odor controllingparticles, abrasive particles). The particle delivery nozzle can beoriented in the CD on either the upstream or the downstream side of thebeam and/or forming box (enclosure).

More than one nozzle can be installed in each beam, enablingcombinations of particles and particle size, shape, mass, and/or StokesNumbers gradients in machine direction thickness of composite streamand/or z-direction thickness of resulting fibrous structure produced bycollecting the composite stream on the collection device 25. The nozzlecan also be designed in such a way that only a section of the nozzledelivers particles, for example to create machine direction stripes inthe resulting fibrous structure.

Each material 72, 24, and 20 in each beam, when present, can becontrolled independently and can be the same or different material fromone or more of the other beams. Each material can also be processed withdifferent settings (angles, velocities e.g.). Also in a single beam,more than one type of particle can be delivered (injected).

Table 3 below sets forth an overview of the Process Examples 1a-6.

Process Examples Overview Table Example Description Utilization (problemsolved) 1a Single beam, SAP particles Keep SAP particles away fromsurface for concentrated in center layer, industrial hygiene, SAPutilization (less waste) weak size gradient and consumer safety 1bSingle beam, SAP particles Larger SAP particles towards top (consumer)for concentrated in center layer, less gel blocking and better capillarygradient SAP size gradient 2 Multi-beam, SAP particles size Spreadliquid in x, y away from skin (small size, gradient and fiber sizegradient, dryness) pulp type gradient 3 Multibeam, low X-link SAP Largefluid holding capacity with effective fluid particles in surface layers,no transfer to surface when cleaning (increase SAP particles in centerlayer, mileage of product) use of pulp and fiber diameter to transportliquid from center to surface (pre-moisteded floor cleainig pad) 4Single beam depositing onto a Enables good hydraulic (fluid transport)pre-existing nonwoven web continuity across the boundary between amaterial such as a Coformed fibrous structure and an adjacentneedlepunched, Nonwoven Web Material as pulp fiber can hydroentangled,air through interpenetrate minimizing liquid transport bonded,spunbonded, carded barriers for efficient liquid transport within anresin bonded, and/or melt absorbent structure. blown nonwoven webmaterial. 5 Dual beam with SAP particles No grainy feel as larger SAPparticles are integration from upstream side primarily located in centerlayer. E.g. SAP in first beam and downstream particles with 0.6 mm (600μm) diameter or side in beam B greater will be noticeable against auser's skin, while SAP particles with 0.2 mm (200 μm) diameter or lesswill be much less noticeable against a user's skin. 6 Stripes of SAPparticles in Enable pads with SAP particles only in regions machinedirection within where needed (e.g. in center of pad) fibrous structure.

Process Example 1a (Low Basis Weight, 100 gsm, Weak Size GradientDistribution, No SAP Particles Close to Surface Regions—Localized Regionof Particles)

Creation of a structure for intended use as absorbent system in hygienicdisposable article, with approximately homogeneous size-distribution ofSAP particles in z-direction. SAP is absent in the near-surface regionto prevent SAP leaking from the material. A single beam in FIG. 13 isutilized for Process Example 1a. Optionally, one or more scrim beams maybe utilized to produce a scrim on either or both sides of the structureformed by Process Example 1a. The details for Process Example 1a are setforth below in Table 4.

TABLE 4 Beam A (bottom layer of product) Beam B: Beam C: Beam ELNAW4841-1A Not used Not used Material Class 72 Material: SSK semi-treated(discrete fibers such pulp (Golden Isle 4725). as pulp) Process: Massflow set to deliver 70 gsm to collection belt Material Class 24Material: PP blend: (continuous filaments LB 650W PP 27.5% MFR 500 suchas melt-blown LB 650X PP 47.5% MFR 1200 PP) Exxon 3155 MFR 35 20%Hydrofilic melt additive 5% Process: Spinning conditions set to deliver30 gsm to collection belt, and air velocities set to deliver app 3.5 mmdiameter (average). Material Class 20 Material: Nippon Shokubai Co(particles such as Ltd, Gr. L705/Nippon/ SAP) 90711868 (wide particlesize distribution) Process: SAP federate adjusted to deliver 25 gsm oncollection belt. Nozzle in CD position at upstream side of beam, angledat 60-90 degrees, app 8 m/s air velocity

The structure formed by Process Example 1a exhibits a non-randomarrangement of the particles in the fibrous structure formed as shown inFIGS. 14A, 14B, and 14C.

Process Example 1b (High Basis Weight, 200 gsm, SAP Particle SizeGradient, Low Presence of SAP in Surface Regions)

Creation of a structure for intended use as absorbent system in hygienicdisposable article, with larger SAP particles distributed towards thetop of the material, and smaller SAP particles towards the bottom toprevent gel-blocking and better utilization of material. A single beamin FIG. 13 is utilized for Process Example 1b. Optionally, one or morescrim beams may be utilized to produce a scrim on either or both sidesof the structure formed by Process Example 1b. The details for ProcessExample 1b are set forth below in Table 5.

TABLE 5 Beam A (bottom layer of product) Beam B: Beam C: Beam ELNAW4841-1A Not used Not used Material Class 72 Material: SSK semi-treated(discrete fibers such pulp (Golden Isle 4725). as pulp) Process: Massflow set to deliver 140 gsm to collection belt Material Class 24Material: PP blend: (continuous filaments LB 650W PP 27.5% MFR 500 suchas melt-blown LB 650X PP 47.5% MFR 1200 PP) Exxon 3155 MFR 35 20%Hydrophilic melt additive 5% Process: Spinning conditions set to deliver60 gsm to collection belt, and air velocities set to deliver app 3.5 mmdiameter (average). Material Class 20 Material: Nippon Shokubai Co(particles such as Ltd, Gr. L705/Nippon/ SAP) 90711868 (wide particlesize distribution) Process: SAP federate adjusted to deliver 80 gsm oncollection belt. Nozzle in CD position at upstream side of beam, angledat 90-120 degrees, app 8 m/s air velocity

The structure formed by Process Example 1b exhibits a non-randomarrangement of the particles in the fibrous structure formed as shown inFIGS. 15A, 15B, and 4C.

Process Example 2

Creation of a structure for intended use as absorbent system in hygienicdisposable article, with efficient initial movement of liquid intomaterial in z-direction, and spreading of liquid towards bottom ofmaterial away from skin. Multiple beams (three in this case) in FIG. 13are utilized for Process Example 2. Optionally, one or more scrim beamsmay be utilized to produce a scrim on either or both sides of thestructure formed by Process Example 2. The details for Process Example 2are set forth below in Table 6.

TABLE 6 A (bottom layer of B (Middle layer of C (top layer of Beamproduct) product) product) Material class 72 Small pulp fibers Standardpulp such as Heavily treated (discrete fibers such such as Eucalyptus,semi-treated SSK, cellulose fibers that as pulp) providing small PVD,mass flow to deliver resist wet collapse, high capillary 35 gsm tocollection such as CS10, mass suction, mass flow to belt flow to deliver35 deliver 35 gsm to gsm to collection belt collection belt Materialclass 24 PP blend with melt PP blend with melt PP blend with melt(continuous filaments additive, spinning additive, spinning additive,spinning such as melt-blown conditions to create conditions to createconditions to create PP) thin filaments of 3-5 medium size thick fibersof 10-20 micrometer diameter, filaments of 5-10 micrometer diameter,mass flow adjusted to micrometers, mass mass flow adjusted o deliver 15gsm to flow adjusted to deliver 15 gsm to collection belt deliver 15 gsmto collection belt collection belt Material class 20 SAP with wide SAPwith more No SAP introduced (particles such as particle size narrowparticle size SAP) distribution, nozzle in distribution, with CDposition at high average particle upstream side of size, nozzle in CDbeam, angled at 90- position at upstream 120 degrees, side of beam,angled massflow adjusted to at 90-120 degrees, deliver 40 gsm tomassflow adjusted to collection belt deliver 40 gsm to collection belt

Resulting structure (modelled SAP size distribution) and exhibited atotal basis weight of 150 gsm with 80 gsm SAP particles added).

Process Example 3

Creation of a structure for intended use as pre-moistened cleaning pad(for example a floor cleaning pad) for cleaning of floors and other hardsurfaces. Cleaning pad to be usable on both sides, and with highcapacity to store liquid at manufacturing and storage, and efficientrelease during product use. Liquid transport occurring from storagelayer in center of pad to surface layers that are in contact withsurface to be cleaned (e.g. floor). Multiple beams (three in this case)in FIG. 13 are utilized for Process Example 3. Optionally, one or morescrim beams may be utilized to produce a scrim on either or both sidesof the structure formed by Process Example 3. The details for ProcessExample 3 are set forth below in Table 7.

TABLE 7 A (bottom layer of B (Middle layer of C (top layer of Beamproduct) product) product) Material class 72 Small pulp fibers Standardpulp such as Small pulp fibers (discrete fibers such such as Eucalyptus,semi-treated SSK such as Eucalyptus, as pulp) providing small PVD,providing small PVD, high capillary suction high capillary suctionMaterial class 24 PP blend with melt PP blend with melt PP blend withmelt (continuous filaments additive, spinning additive, spinningadditive, spinning such as melt-blown conditions to create conditions tocreate conditions to create PP) thin filaments of 3-5 medium size thinfilaments of 3-5 micrometer diameter filaments of 5-10 micrometerdiameter micrometers Material class 20 low X-link SAP with No SAPintroduced low X-link SAP with (particles such as wide particle sizewide particle size SAP) distribution, nozzle in distribution, nozzle inCD position at CD position at downstream side of upstream side of beam,angled at 90- beam, angled at 90- 120 degrees. Smaller 120 degrees.Smaller SAP particles are SAP particles are thus kept away from thuskept away from surface of product to surface of product to preventsmearing prevent smearing

Process Example 4

Creation of a structure for intended use as absorbent system in hygienicdisposable article, where SAP with wide particle size distribution isused, where the smaller SAP particles are absent from the surface layerin order to prevent gel blocking, using a single beam. Single beam inFIG. 13 is utilized for Process Example 4. Optionally, one or more scrimbeams may be utilized to produce a scrim on either or both sides of thestructure formed by Process Example 4.

The process deposits the materials onto a pre-existing nonwoven webmaterial, for example a topsheet, such as a 24 gsm carded nonwovensecondary topsheet from YanJan, riding on a collection device.

The details for Process Example 4 are set forth below in Table 8.

TABLE 8 A (bottom layer of B (Middle layer of C (top layer of Beamproduct) product) product) Material class 72 Standard pulp such as Notused Not used (discrete fibers such semi-treated SSK as pulp) Materialclass 24 PP blend with melt Not used Not used (continuous filamentsadditive, spinning such as melt-blown conditions to create PP) thinfilaments of 5-10 micrometer diameter Material class 20 SAP with wideNot used Not used (particles such as particle size SAP) distribution,nozzle in CD position at upstream side of beam, angled at 70- 110degrees with high velocity air. Smaller SAP particles are thus kept awayfrom zone close to surface of product to prevent gel blocking

Example 5

Creation of a structure for intended use as absorbent system in hygienicdisposable article, where SAP with wide particle size distribution isused, where the larger SAP particles are absent from the surface layerin order to prevent a grainy hard feel of the material by embedding thelarger SAP particles in the middle of the fibrous structure. Multiplebeams (two in this case) in FIG. 13 are utilized for Process Example 5.Optionally, one or more scrim beams may be utilized to produce a scrimon either or both sides of the structure formed by Process Example 5.The details for Process Example 5 are set forth below in Table 9.

TABLE 9 A (bottom layer of B (Middle layer of C (top layer of Beamproduct) product) product) Material class 72 Standard pulp such asStandard pulp such as Not used (discrete fibers such semi-treated SSKsemi-treated SSK as pulp) Material class 24 PP blend with melt PP blendwith melt Not used (continuous filaments additive, spinning additive,spinning such as melt-blown conditions to create conditions to createPP) thin filaments of 5-10 thin filaments of 5-10 micrometer diametermicrometer diameter Material class 20 SAP with wide SAP with wide Notused (particles such as particle size particle size SAP) distribution,nozzle in distribution, nozzle in CD position at CD position at upstreamside of downstream side of beam, angled at 70- beam, angled at 70- 110degrees with 110 degrees with high velocity air (10- high velocity air(10- 15 m/s). Smaller SAP 15 m/s). Smaller SAP particles are thus keptparticles are thus kept away from zone close away from zone close tosurface of product to surface of product to prevent gel to prevent gelblocking blocking

Process Example 6

Creation of a structure for intended use as absorbent system in hygienicdisposable article, where SAP is present only in a portion of theproduct (e.g. towards the center) to reduce cost of SAP material thatdoes not contribute to product performance. Multiple beams (two in thiscase) in FIG. 13 are utilized for Process Example 6. Optionally, one ormore scrim beams may be utilized to produce a scrim on either or bothsides of the structure formed by Process Example 6. The details forProcess Example 6 are set forth below in Table 10.

TABLE 10 A (bottom layer of B (Middle layer of C (top layer of Beamproduct) product) product) Material class 72 Standard pulp such asStandard pulp such as Not used (discrete fibers such semi-treated SSKsemi-treated SSK as pulp) Material class 24 PP blend with melt PP blendwith melt Not used (continuous filaments additive, spinning additive,spinning such as melt-blown conditions to create conditions to createPP) thin filaments of 5-10 thin filaments of 5-10 micrometer diametermicrometer diameter Material class 20 SAP with wide Not used Not used(particles such as particle size SAP) distribution, nozzle in CDposition at downstream side of beam, with slots in nozzle depositing SAPon zones of app 50-70 mm width, separated by 50-70 mm zones absent ofSAP

Structures

The structures, for example fibrous structures, such as an absorbentmaterial, for example an absorbent core material, of the presentinvention made by the inventive process of the present inventioncomprise a plurality of filaments and a plurality of particles. In oneexample, the plurality of filaments and the plurality of particles arecommingled together to form a coform structure. In addition to thefilaments and the particles, the structures of the present invention mayfurther comprise a plurality of non-particle solid additives, such asfibers, for example pulp fibers, such as wood pulp fibers.

The structures, for example a fibrous structures, such as non-elasticfibrous structures, of the present invention comprise a plurality offilaments and a plurality of super absorbent polymer particles, andoptionally a plurality of pulp fibers. The filaments and the superabsorbent polymer particles, and optionally the pulp fibers, may becommingled together. In one example, the structure is a coformstructure. The filaments may be present in the structures of the presentinvention at a level of less than 90% and/or less than 80% and/or lessthan 65% and/or less than 50% and/or greater than 5% and/or greater than10% and/or greater than 20% and/or from about 10% to about 50% and/orfrom about 25% to about 45% by weight of the structure on a dry basis.

The particles may be present in the structures of the present inventionat a level of greater than 10% and/or greater than 25% and/or greaterthan 50% and/or less than 100% and/or less than 95% and/or less than 90%and/or less than 85% and/or from about 30% to about 95% and/or fromabout 50% to about 85% by weight of the structure on a dry basis.

The non-particle solid additives, when present, may be present in thestructures of the present invention at a level of greater than 10%and/or greater than 25% and/or greater than 50% and/or less than 100%and/or less than 95% and/or less than 90% and/or less than 85% and/orfrom about 30% to about 95% and/or from about 50% to about 85% by weightof the structure on a dry basis.

The filaments and particles may be present in the structures of thepresent invention at a weight ratio of filaments to particles of greaterthan 10:90 and/or greater than 20:80 and/or less than 90:10 and/or lessthan 80:20 and/or from about 25:75 to about 50:50 and/or from about30:70 to about 45:55. In one example, the filaments and particles arepresent in the structures of the present invention at a weight ratio offilaments to particles of greater than 0 but less than 1.

The filaments and non-particle solid additives, when present, may bepresent in the structures of the present invention at a weight ratio offilaments to non-particle solid additives of greater than 10:90 and/orgreater than 20:80 and/or less than 90:10 and/or less than 80:20 and/orfrom about 25:75 to about 50:50 and/or from about 30:70 to about 45:55.In one example, the filaments and non-particle solid additives, whenpresent, are present in the structures of the present invention at aweight ratio of filaments to non-particle solid additives of greaterthan 0 but less than 1.

In one example, the structures of the present invention exhibit a basisweight of from about 10 gsm to about 1000 gsm and/or from about 10 gsmto about 500 gsm and/or from about 15 gsm to about 400 gsm and/or fromabout 15 gsm to about 300 gsm as measured according to the Basis WeightTest Method described herein. In another example, the structures of thepresent invention exhibit a basis weight of from about 10 gsm to about200 gsm and/or from about 20 gsm to about 150 gsm and/or from about 25gsm to about 125 gsm and/or from about 30 gsm to about 100 gsm and/orfrom about 30 gsm to about 80 gsm as measured according to the BasisWeight Test Method described herein. In still another example, thestructures of the present invention exhibit a basis weight of from about80 gsm to about 1000 gsm and/or from about 125 gsm to about 800 gsmand/or from about 150 gsm to about 500 gsm and/or from about 150 gsm toabout 300 gsm as measured according to the Basis Weight Test Methoddescribed herein.

In one example the structure of the present invention is a coformfibrous structure, for example a non-elastic coform fibrous structure,comprises a core component comprising a plurality of particles, such asSAP particles, and optionally non-particle solid additives, for examplefibers, such as pulp fibers, for example wood pulp fibers, and aplurality of core filaments, that are commingled with the particles andthe non-particle solid additives, when present. The coform fibrousstructure may further comprise a scrim component, which may be void orsubstantially void of particles and non-particle solid additives,comprising a plurality of scrim filaments, which may be the same and/ordifferent for example in chemical composition as the core filaments andwhich are deposited, for example spun, directly onto one or moresurfaces of the core component. The scrim component, for example thescrim filaments, may be bonded, for example thermally bonded, to thecore component, for example the core component filaments and/orparticles and/or non-particle solid additives, when present.

In one example, the core component is the component that exhibits thegreatest basis weight within the coform fibrous structure. In oneexample, the core component present in the coform fibrous structure ofthe present invention exhibits a basis weight that is greater than 50%and/or greater than 55% and/or greater than 60% and/or greater than 65%and/or greater than 70% and/or less than 100% and/or less than 95%and/or less than 90% of the total basis weight of the coform fibrousstructure as measured according to the Basis Weight Test Methoddescribed herein. In another example, the core component exhibits abasis weight of less than 20 gsm and/or less than 15 gsm and/or lessthan 12 gsm and/or less than 10 gsm and/or less than 8 gsm and/or lessthan 6 gsm and/or greater than 2 gsm and/or greater than 4 gsm asmeasured according to the Basis Weight Test Method described herein.

In one example, at least one of the core components of the coformfibrous structure comprises a plurality of non-particle solid additives,for example pulp fibers, such as comprise wood pulp fibers and/ornon-wood pulp fibers.

In one example, the scrim component exhibits a basis weight that is lessthan 25% and/or less than 20% and/or less than 15% and/or less than 10%and/or less than 7% and/or less than 5% and/or greater than 0% and/orgreater than 1% of the total basis weight of the coform fibrousstructure as measured according to the Basis Weight Test Methoddescribed herein. In another example, the scrim component exhibits abasis weight of 10 gsm or less and/or less than 10 gsm and/or less than8 gsm and/or less than 6 gsm and/or greater than 5 gsm and/or less than4 gsm and/or greater than 0 gsm and/or greater than 1 gsm as measuredaccording to the Basis Weight Test Method described herein.

In one example, at least one scrim component is adjacent to at least onecore component within the coform fibrous structure. In another example,at least one core component is positioned between two scrim componentswithin the coform fibrous structure.

In one example, at least one of the scrim filaments exhibits an averagefiber diameter of less than 50 and/or less than 25 and/or less than 10and/or at least 1 and/or greater than 1 and/or greater than 3 μm asmeasured according to the Average Diameter Test Method described herein.

The average fiber diameter of the core filaments is less than 250 and/orless than 200 and/or less than 150 and/or less than 100 and/or less than50 and/or less than 30 and/or less than 25 and/or less than 10 and/orgreater than 1 and/or greater than 3 μm as measured according to theAverage Diameter Test Method described herein.

In one example, the coform fibrous structures of the present inventionmay comprise any suitable amount of filaments (core filaments and/orscrim filaments) and any suitable amount of solid additives. Forexample, the coform fibrous structures may comprise from about 10% toabout 70% and/or from about 20% to about 60% and/or from about 30% toabout 50% by dry weight of the coform fibrous structure of filaments andfrom about 90% to about 30% and/or from about 80% to about 40% and/orfrom about 70% to about 50% by dry weight of the coform fibrousstructure of solid additives, such as wood pulp fibers.

In one example, the filaments and particles of the present invention maybe present in the coform fibrous structures according to the presentinvention at weight ratios of filaments to particles of from at leastabout 1:1 and/or at least about 1:1.5 and/or at least about 1:2 and/orat least about 1:2.5 and/or at least about 1:3 and/or at least about 1:4and/or at least about 1:5 and/or at least about 1:7 and/or at leastabout 1:10.

In one example, the non-particle solid additives, when present in thecoform fibrous structure may be present in the coform fibrous structuresaccording to the present invention at weight ratios of filaments tonon-particle solid additives of from at least about 1:1 and/or at leastabout 1:1.5 and/or at least about 1:2 and/or at least about 1:2.5 and/orat least about 1:3 and/or at least about 1:4 and/or at least about 1:5and/or at least about 1:7 and/or at least about 1:10.

In one example, the non-particle solid additives, for example fibers,such as pulp fibers, for example wood pulp fibers, may be selected fromthe group consisting of softwood kraft pulp fibers, hardwood pulpfibers, and mixtures thereof. Non-limiting examples of hardwood pulpfibers include fibers derived from a fiber source selected from thegroup consisting of: Acacia, Eucalyptus, Maple, Oak, Aspen, Birch,Cottonwood, Alder, Ash, Cherry, Elm, Hickory, Poplar, Gum, Walnut,Locust, Sycamore, Beech, Catalpa, Sassafras, Gmelina, Albizia,Anthocephalus, and Magnolia. Non-limiting examples of softwood pulpfibers include fibers derived from a fiber source selected from thegroup consisting of: Pine, Spruce, Fir, Tamarack, Hemlock, Cypress, andCedar. In one example, the hardwood pulp fibers comprise tropicalhardwood pulp fibers. Non-limiting examples of suitable tropicalhardwood pulp fibers include Eucalyptus pulp fibers, Acacia pulp fibers,and mixtures thereof.

In one example, the wood pulp fibers comprise softwood pulp fibersderived from the kraft process and originating from southern climates,such as Southern Softwood Kraft (SSK) pulp fibers. In another example,the wood pulp fibers comprise softwood pulp fibers derived from thekraft process and originating from northern climates, such as NorthernSoftwood Kraft (NSK) pulp fibers.

The wood pulp fibers present in the coform fibrous structure may bepresent at a weight ratio of softwood pulp fibers to hardwood pulpfibers of from 100:0 and/or from 90:10 and/or from 86:14 and/or from80:20 and/or from 75:25 and/or from 70:30 and/or from 60:40 and/or about50:50 and/or to 0:100 and/or to 10:90 and/or to 14:86 and/or to 20:80and/or to 25:75 and/or to 30:70 and/or to 40:60. In one example, theweight ratio of softwood pulp fibers to hardwood pulp fibers is from86:14 to 70:30.

In one example, the fibrous structures of the present invention compriseone or more trichomes. Non-limiting examples of suitable sources forobtaining trichomes, especially trichome fibers, are plants in theLabiatae (Lamiaceae) family commonly referred to as the mint familyExamples of suitable species in the Labiatae family include Stachysbyzantina, also known as Stachys lanata commonly referred to as lamb'sear, woolly betony, or woundwort. The term Stachys byzantina as usedherein also includes cultivars Stachys byzantina ‘Primrose Heron’,Stachys byzantina ‘Helene von Stein’ (sometimes referred to as Stachysbyzantina ‘Big Ears’), Stachys byzantina ‘Cotton Boll’, Stachysbyzantina ‘Variegated’ (sometimes referred to as Stachys byzantina‘Striped Phantom’), and Stachys byzantina ‘Silver Carpet’.

Non-limiting examples of suitable polypropylenes for making thefilaments, for example filaments of the present invention arecommercially available from LyondellBasell and Exxon-Mobil.

Any hydrophobic or non-hydrophilic materials within the coform fibrousstructure, such as the thermoplastic filaments, for example thepolypropylene filaments, may be surface treated and/or melt treated witha hydrophilic modifier. Non-limiting examples of surface treatinghydrophilic modifiers include surfactants, such as Triton X-100.Non-limiting examples of melt treating hydrophilic modifiers that areadded to the polymer composition (polymer melt), such as thepolypropylene melt, prior to spinning filaments, include hydrophilicmodifying melt additives such as VW351 and/or S-1416 commerciallyavailable from Polyvel, Inc. and Irgasurf commercially available fromCiba. The hydrophilic modifier may be associated with the hydrophobic ornon-hydrophilic material at any suitable level known in the art. In oneexample, the hydrophilic modifier is associated with the polymercomposition, such as the hydrophobic and/or non-hydrophilic materialwithin the polymer composition at a level of greater than 0% to lessthan about 20% and/or greater than 0% to less than about 15% and/orgreater than 0.1% to less than about 10% and/or greater than 0.1% toless than about 5% and/or greater than 0.5% to less than about 3% by dryweight of the hydrophobic or non-hydrophilic material. In anotherexample, the hydrophilic modifier may be present in the filaments at alevel of from about 0.1% to about 10% and/or from about 0.5% to about 7%and/or from about 1% to about 5% by weight of the filaments.

In one example, a fibrous structure according to the present inventioncomprises a plurality of filaments and a plurality of solid particleswherein the plurality of filaments and the plurality of solid particlesare commingled together to form the fibrous structure such that theplurality of solid particles are present through the fibrous structure'sthickness at different average particle size values.

The plurality of filaments may comprise a plurality of filaments, forexample water-insoluble filaments.

The plurality of filaments may comprise a plurality of fibers, forexample water-insoluble fibers.

The filaments may comprise a polymer, for example a thermoplasticpolymer, such as a thermoplastic polymer is selected from the groupconsisting of: polyolefins, polyesteramides, polycaprolactones,polyhydroxyalkanoates, polylactic acids, and mixtures thereof. In oneexample, the thermoplastic polymer is a polyolefin, such as a polyolefinselected from the group consisting of: polypropylene, polypropylenecopolymers, polyethylene, polyethylene copolymers, and mixtures thereof.

In one example, the thermoplastic polymer is a biodegradablethermoplastic polymer.

In one example, the thermoplastic polymer is a compostable thermoplasticpolymer.

In one example, the fibrous structure comprises a plurality of particlesselected from the group consisting of: inorganic particles, organicparticles, and mixtures thereof.

In one example, the fibrous structure comprises a plurality of solidparticles comprising odor controlling particles and/or perfumeparticles, and/or abrasive particles.

In one example, the SAP particles of the fibrous structure compriseabsorbent material particles, for example absorbent material particlescomprising a superabsorbent polymer particles, such as carboxylic acid,for example crosslinked carboxylic acid.

In one example, the SAP particles exhibit a D50 particle size of fromabout 20 μm to about 2000 μm and/or from about 50 μm to about 2000 μmand/or from about 100 μm to about 2000 μm and/or from about 250 μm toabout 1200 μm and/or from about 250 μm to about 850 μm and/or from about150 μm to about 850 μm and/or from about 100 μm to about 600 μm and/orfrom about 100 μm to about 400 μm as measured according to the ParticleSize Distribution Test Method.

In one example, the SAP particles are present in the fibrous structureat a basis weight of from about 10 gsm to about 1000 gsm.

The fibrous structure of the present invention may comprise a firstgroup of solid particles comprising a first composition, such as the SAPparticles, and second group of solid particles comprising a secondcomposition different from the first composition.

In one example, the SAP particles comprise a first group of SAPparticles that exhibit a first Stokes Number and second group of SAPparticles that exhibit a second Stokes Number different from the firstStokes Number. In one example, the first Stokes Number is at least 20%and/or at least 30% different from the second Stokes Number.

The plurality of SAP particles may be present in the fibrous structure'sthickness in an average particle size value gradient.

The plurality of solid particles may be present in the fibrousstructure's thickness in an average particle size value continuousgradient

The fibrous structure may further comprise a plurality of pulp fiberscommingled together with the plurality of filaments and the plurality ofSAP particles.

The plurality of pulp fibers may comprise wood pulp fibers.

The plurality of pulp fibers may comprise non-wood pulp fibers.

In one example, the particles are added in the process such that theresulting structure, for example fibrous structure, comprises anon-uniform concentration of the particles in the fibrous structure'sz-direction.

In one example, the particles are added in the process such that theresulting structure, for example fibrous structure, comprises a firstregion comprising particles that exhibit a first particle size and asecond region different from the first region comprising particles thatexhibit a second particle size different from the first particle size.

FIG. 16 shows non-limiting examples of particles 20, for example SAPparticles, and non-particle solid additives, for example pulp fibers 72.As can be seen from FIG. 16, one reason for SAP particles having alarger stokes number is their larger geometric mean of major and minoraxis vs pulp fibers.

Test Methods

Unless otherwise specified, all tests described herein including thosedescribed under the Definitions section and the following test methodsare conducted on samples that have been conditioned in a conditionedroom at a temperature of 23° C.±1.0° C. and a relative humidity of50%±2% for a minimum of 24 hours prior to the test. These will beconsidered standard conditioning temperature and humidity. All plasticand paper board packaging articles of manufacture, if any, must becarefully removed from the samples prior to testing. Except where notedall tests are conducted in such conditioned room, under the sameenvironmental conditions in such conditioned room. Discard any damagedproduct. Do not test samples that have defects such as wrinkles, tears,holes, and like. All instruments are calibrated according tomanufacturer's specifications. The stated number of replicate samples tobe tested is the minimum number.

Basis Weight Test Method

Basis weight of a structure, such as a fibrous structure, for example anabsorbent material, such as an absorbent core material is measured onstacks of eight to twelve structures using a top loading analyticalbalance with a resolution of ±0.001 g. A precision cutting die,measuring 8.890 cm by 8.890 cm or 10.16 cm by 10.16 cm is used toprepare all samples.

Condition samples under the standard conditioning temperature andhumidity for a minimum of 10 minutes prior to cutting the sample. With aprecision cutting die, cut the samples into squares. Combine the cutsquares to form a stack eight to twelve samples thick. Measure the massof the sample stack and record the result to the nearest 0.001 g.

Calculations:

${{Basis}\mspace{14mu}{Weight}}\;,{\text{g/m}^{2} = \frac{{mass}\mspace{14mu}{of}\mspace{14mu}{stack}}{\left( {{area}\mspace{14mu}{of}\mspace{14mu} 1\mspace{14mu}{square}\mspace{14mu}{in}\mspace{14mu}{stack}} \right)\left( {\#\mspace{11mu}{squares}\mspace{14mu}{in}\mspace{14mu}{stack}} \right)}}$

Report result to the nearest 0.1 g/m². Sample dimensions can be changedor varied using a similar precision cutter as mentioned above, so as atleast 645 square centimeters of sample area is in the stack.

Individual fibrous structures that are ultimately combined to form andarticle may be collected during their respective making operation priorto combining with other fibrous structures and then the basis weight ofthe respective fibrous structure is measured as outlined above.

Average Diameter Test Method

There are many ways to measure the diameter of a fibrous element, forexample a filament and/or fiber. One way is by optical measurement. Afibrous structure comprising fibrous elements, for example filaments, iscut into a rectangular shape sample, approximately 20 mm by 35 mm. Thesample is then coated using a SEM sputter coater (EMS Inc, PA, USA) orequivalent with gold so as to make the filaments relatively opaque.Typical coating thickness is between 50 and 250 nm. The sample is thenmounted between two standard microscope slides and compressed togetherusing small binder clips. The sample is imaged using a 10× objective onan Olympus BHS microscope or equivalent with the microscopelight-collimating lens moved as far from the objective lens as possible.Images are captured using a Nikon D1 digital camera or equivalent. Aglass microscope micrometer is used to calibrate the spatial distancesof the images. The approximate resolution of the images is 1 μm/pixel.Images will typically show a distinct bimodal distribution in theintensity histogram corresponding to the filaments and the background.Camera adjustments or different basis weights are used to achieve anacceptable bimodal distribution. Typically 10 images per sample aretaken and the image analysis results averaged.

The images are analyzed in a similar manner to that described by B.Pourdeyhimi, R. and R. Dent in “Measuring fiber diameter distribution innonwovens” (Textile Res. J. 69(4) 233-236, 1999). Digital images areanalyzed by computer using the MATLAB (Version. 6.1) or equivalent andthe MATLAB Image Processing Tool Box (Version 3) or equivalent. Theimage is first converted into a grayscale. The image is then binarizedinto black and white pixels using a threshold value that minimizes theintraclass variance of the thresholded black and white pixels. Once theimage has been binarized, the image is skeletonized to locate the centerof each fiber in the image. The distance transform of the binarizedimage is also computed. The scalar product of the skeletonized image andthe distance map provides an image whose pixel intensity is either zeroor the radius of the fiber at that location. Pixels within one radius ofthe junction between two overlapping fibers are not counted if thedistance they represent is smaller than the radius of the junction. Theremaining pixels are then used to compute a length-weighted histogram offilament diameters contained in the image.

Micro-CT (μCT) Test Method

3D x-ray sample imaging is obtained on a micro-CT instrument such as theScanco μCT 50 or Scanco μCT 100HE (Scanco Medical AG, Switzerland). Themicro-CT instrument is a cone beam microtomograph with a shieldedcabinet. A maintenance-free x-ray tube is used as the source with anadjustable focal spot diameter. The x-ray beam passes through thesample, where some of the x-rays are attenuated based on the samplecomposition, structure and total volume. In other words, the extent ofattenuation correlates to the mass density of the sample the x-rays passthrough. The transmitted/attenuated x-rays continue to the digitaldetector array and generate a 2D projection image of the sample. A 3Dimage of the sample is generated by collecting hundreds of individual 2Dprojections at different directional angles as the sample is rotated.These direction dependent 2D projections are then reconstructed into asingle 3D image. The instrument is interfaced with a computer runningsoftware to control the image acquisition and save the raw data.

Micro-Computed for Determining Average Particle Size Distributions withFibrous Structures (FS):

Porosity is the ratio between void-space to the total space occupied bya fibrous structure. Porosity under this test method is calculated fromμCT scans of a fibrous structure by segmenting the void space viathresholding and determining the ratio of void voxels to total voxels.Similarly, solid volume fraction (SVF) is calculated from μCT scans of afibrous structure and is the ratio between solid space to the totalspace, and SVF is calculated as the ratio of solid voxels to totalvoxels. Both Porosity and SVF are an average scalar-value that do notprovide structural information, different from, “pore-size distribution”in the height-direction of the fibrous structure, or the “averagethickness of fibrous structure fibers” in the machine direction (MD) or“particle (for example SAP particle) size distribution” as a function offibrous structure depth.

To characterize the 3D structure of the fibrous structure, samples areimaged using a μCT X-ray scanning instrument capable of acquiring adataset at high isotropic spatial resolution. One example of suitableinstrumentation is the SCANCO system model 50 μCT scanner or 100HE μCT(Scanco Medical AG, Brüttisellen, Switzerland) operated with thefollowing settings: energy level of 45 kVp at 104 μA; 3000 projections;19 mm field of view; 400 ms integration time; an averaging of 6; and avoxel size of 6 μm per pixel. After scanning and subsequent datareconstruction is complete, the scanner system creates a 16 bit dataset, referred to as an ISQ file, where grey levels reflect changes inx-ray attenuation, which in turn relates to material density. The ISQfile is then converted to 8 bit using a scaling factor.

Scanned fibrous structure samples are normally prepared by punching acore of approximately 32 mm in diameter from the fibrous structure to bescanned. The fibrous structure punch is laid flat on a low-attenuatingfoam and then mounted in a 34 mm diameter plastic cylindrical tube forscanning Scans of the fibrous structure punch samples are acquired suchthat a 19 mm inner volume is included in the dataset as to avoidstructural modifications from the edge while punching-out the sample.From this dataset, a smaller sub-volume of the sample dataset isextracted from the total cross section of the scanned fibrous structurepunch, creating a 3D slab of data, where the fibrous structure can bequalitatively assessed, accurately and promptly.

To characterize particle, for example SAP particle distribution, theparticle, for example SAP particle must be separated from the fibrousstructure. This was easily accomplished by thresholding andsegmentation. The particle, for example SAP particle has a higher massdensity than that of the surrounding fibrous elements, thus a highthreshold is implemented to separate particle components from thefibrous structure, for example fibrous elements. To then characterizeparticle distribution in the height-direction, Local Thickness Mapalgorithm, or LTM, was implemented on the subvolume dataset. The LTMMethod starts with a Euclidean Distance Mapping (EDM) which assigns greylevel values equal to the distance each solid-voxel is from its nearestboundary. Based on the EDM data, the 3D solid space representingparticle is tessellated with spheres sized to match the EDM values.Voxels enclosed by the spheres are assigned the radius value of thelargest sphere. In other words, each solid voxel is assigned the radialvalue of the largest sphere that both fits within the solid spaceboundary and includes the assigned voxel. The 3D labelled spheredistribution output from the LTM data scan can be treated as a stack oftwo-dimensional images in the height-direction (or Z-direction) and usedto estimate the change in sphere diameter from slice to slice as afunction of fibrous structure depth. The particle thickness is treatedas a 3D dataset and an average value can be assessed for the whole orparts of the subvolume. The calculations and measurements were doneusing AVIZO Lite (9.2.0) from Thermo Fisher Scientific and MATLAB(R2018b) from Mathworks.

Also, to characterize particle distribution, the thresholded smallerparticle dataset can be used to identify connected or separatecomponents. For instance, a connected object is a set of adjacent voxelswith intensity values lying inside the selected threshold range. Oncethe regions are identified, statistical quantities for the regions areoutputted such as individual particle Volumes (Number of voxels timessize of a single voxel) and CenterX, CenterY, Center: [X, Y, Z]correspond to coordinate of the particle's center. Data processing inMatlab can provide detailed histograms of distributions as a function ofdepth.

On the other hand, the thresholded smaller dataset can be used togenerate Iso-surface in Avizo without smoothing. An isosurface is a 3Danalog to an isocontour that is rendered for a mesh of polygons. TheSurface Area to Contained Volume function in Avizo adds up the area ofall patche's triangles, and also assessed the volume surrounded by thetriangles, and outputs the data in an excel sheet.

Particle Size Distribution Test Method: The particle size distributiontest is conducted to determine characteristic sizes of solid additives,for example particles. It is conducted using ASTM D 502-89, “StandardTest Method for Particle Size of Soaps and Other Detergents”, approvedMay 26, 1989, with a further specification for sieve sizes and sievetime used in the analysis. Following section 7, “Procedure usingmachine-sieving method,” a nest of clean dry sieves containing U.S.Standard (ASTM E 11) sieves #4 (4.75 mm), #6 (3.35 mm), #8 (2.36 mm),#12 (1.7 mm), #16 (1.18 mm), #20 (850 micrometer), #30 (600 micrometer),#40 (425 micrometer), #50 (300 micrometer), #70 (212 micrometer), #100(150 micrometer), #170 (90 micrometer), #325 (44 micrometer) and pan isrequired to cover the range of particle sizes referenced herein. Theprescribed Machine-Sieving Method is used with the above sieve nest. Asuitable sieve-shaking machine can be obtained from W.S. Tyler Company,Ohio, U.S.A. The sieve-shaking test sample is approximately 100 gramsand is shaken for 5 minutes.

The data are plotted on a semi-log plot with the micrometer size openingof each sieve plotted on the logarithmic abscissa and the cumulativemass percent finer (CMPF) is plotted on the linear ordinate. An exampleof the above data representation is given in ISO 9276-1:1998,“Representation of results of particle size analysis—Part 1: GraphicalRepresentation”, FIG. A.4. A characteristic particle size (Dx, x=10, 50,90), for the purpose of this invention, is defined as the abscissa valueat the point where the cumulative mass percent is equal to x percent,and is calculated by a straight line interpolation between the datapoints directly above (a) and below (b) the x value using the followingequation:

Dx=10{circumflex over ( )}[Log(Da)−(Log(Da)−Log(db))*(Qa−x%)/(Qa−Qb)]

where Log is the base 10 logarithm, Qa and Qb are the cumulative masspercentile values of the measured data immediately above and below thex^(th) percentile, respectively; and Da and db are the micrometer sievesize values corresponding to these data.

Example Data and Calculations

sieve size weight on cumulative mass % (micrometer) sieve (g) finer(CMPF) 1700 0  100% 1180 0.68 99.3% 850 10.40 89.0% 600 28.73 60.3% 42527.97 32.4% 300 17.20 15.2% 212 8.42  6.8% 150 4.00  2.8% Pan 2.84  0.0%

For D10 (x=10), the micrometer screen size where CMPF is immediatelyabove 10% (Da) is 300 micrometer, the screen below (db) is 212micrometer. The cumulative mass immediately above 10% (Qa) is 15.2%,below (Qb) is 6.8%. D10=10{circumflex over( )}[Log(300)−(Log(300)−Log(212))*(15.2%−10%)/(15.2%−6.8%)]=242micrometer.

For D90 (x=90), the micrometer screen size where CMPF is immediatelyabove 90% (Da) is 1180 micrometer, the screen below (db) is 850micrometer. The cumulative mass immediately above 90% (Qa) is 99.3%,below (Qb) is 89.0%. D90=10{circumflex over( )}[Log(1180)−(Log(1180)−Log(850))*(99.3%−90%)/(99.3%−89.0%)]=878micrometer.

For D50 (x=50), the micrometer screen size where CMPF is immediatelyabove 50% (Da) is 600 micrometer, the screen below (db) is 425micrometer. The cumulative mass immediately above 50% (Qa) is 60.3%,below (Qb) is 32.4%. D50=10{circumflex over( )}[Log(600)−(Log(600)−Log(425))*(60.3%−50%)/(60.3%−32.4%)]=528micrometer.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process for forming a composite fluid stream,the process comprising the step of mixing a first fluid streamcomprising a plurality of fibrous elements with a second fluid streamcomprising a plurality of first particles such that a composite fluidstream exhibiting a non-random arrangement of the plurality of firstparticles in the composite fluid stream is formed.
 2. The processaccording to claim 1 wherein the plurality of fibrous elements comprisesa plurality of filaments.
 3. The process according to claim 1 whereinthe plurality of fibrous elements comprises a plurality of filaments anda plurality of fibers.
 4. The process according to claim 3 wherein theplurality of filaments and the plurality of fibers are commingled. 5.The process according to claim 1 wherein the step of mixing a firstfluid stream comprising a plurality of fibrous elements with a secondfluid stream comprising a plurality of first particles occurs within anenclosure.
 6. The process according to claim 1 wherein the step ofmixing a first fluid stream comprising a plurality of fibrous elementswith a second fluid stream comprising a plurality of first particlescomprises coforming the plurality of fibrous elements with the pluralityof first particles.
 7. The process according to claim 1 wherein theplurality of first particles exhibit a range of Stokes Numbers.
 8. Theprocess according to claim 1 wherein the plurality of first particlescomprises absorbent material particles.
 9. The process according toclaim 8 wherein the absorbent material particles comprise superabsorbent polymer particles.
 10. The process according to claim 1wherein the plurality of first particles comprises at least one particlethat exhibits a size that is at least two times greater than the size ofat least one other particle within the plurality of first particles. 11.The process according to claim 1 wherein the first fluid streamcomprises a plurality of filaments commingled with a plurality offibers.
 12. The process according to claim 1 wherein the second fluidstream comprises an air stream comprising the plurality of firstparticles.
 13. The process according to claim 1 wherein the non-randomarrangement of the plurality of first particles in the composite fluidstream is such that the plurality of first particles are present in amachine direction gradient in the composite fluid stream based on aparticle characteristic selected from the group consisting of: size,shape, mass, density, Stokes Number, and mixtures thereof.
 14. Theprocess according to claim 1 wherein the process further comprises thestep of collecting the composite fluid stream on a collection devicesuch that a fibrous structure exhibiting a non-random arrangement of theplurality of first particles in the fibrous structure is formed.
 15. Theprocess according to claim 1 wherein the non-random arrangement of theplurality of first particles in the fibrous structure is such that theplurality of first particles are present in a z-direction gradient inthe fibrous structure based on a particle characteristic selected fromthe group consisting of: size, shape, mass, density, Stokes Number, andmixtures thereof.
 16. The process according to claim 15 wherein thefibrous structure comprises a homogeneous z-direction concentration ofthe first particles.
 17. The process according to claim 15 wherein thefibrous structure comprises a non-homogeneous z-direction concentrationof the first particles.
 18. The process according to claim 15 whereinthe fibrous structure comprises two or more different z-direction layersof concentration of the first particles.
 19. The process according toclaim 1 wherein the process further comprises the step of depositing ascrim layer on at least one surface of the fibrous structure.
 20. Afibrous structure made according to the process according to claim 1.